No contents in here (Delete this text before submission) Design and Optimization of a Formula SAE Vehicle Andrew Casella, Alex Deneault, Patrick Donaghey, Mark Lightbody, Jeffrey Robinson and Cote Taylor Advisors: Professors David Planchard and John Hall Abstract Competition The purpose of this MQP was to design a vehicle for use in the 2018 • Team acts as fictional Formula SAE Michigan competition. The major goals for this MQP manufacturing company were to improve competition performance and to reduce the weight designing and marketing a small of the vehicle from previous years. The suspension, steering, and drivetrain subsystems were considered to have the most room for car for weekend autocross racing improvement, and received the most attention during the design • Extensive design regulations process. Weight was reduced by nearly 100lbs versus the 2016 design, and engine performance shows potential for 10% improvement. • 120 teams & 2300 students attending this year Drivetrain • Judging by auto industry experts • 450cc single-cylinder motorcycle engine Braking • Chain drive with limited slip • Master cylinders packaged differential underneath floor to lower • Eccentric Cam chain center of gravity and save space tensioner integrated into Suspension • Even 95th percentile male driver differential mounts • Pullrod actuated double will fit due to clever packaging wishbone linkage Shifting Air Intake • FEA used to ensure safety and • Dynamic motion analysis & • 5-speed, paddle actuated • Developed time-dependent strategically save weight Finite Element failure sequential shifting flow simulation method to • Brake force ~80% F / ~20% R analysis • Mechanical linkage driven calculate performance data • Parallel pullrod and shock by electric motor actuates • Iterative design for max. absorber design saves space transmission efficiency with min. size Ergonomics and Steering • Raspberry Pi motor • 3D printed components Manufacturing • Miter gears in place of U-joints for lower steering effort controller reinforced with fiberglass • Adjustable Ackermann with steering ratio of 4.6:1 • Upholstered foam seat insert molded to fit drivers • Electronics mounted on firewall beneath seat • Multiple CNC operations utilizing soft jaws and live tooling • Many complex CNC and welding operations • Water jet and laser cutting used to make many 2D parts • 3D printing used for some key components.