Design and Optimization of an FSAE Vehicle A Major Qualifying Project Submitted to the Faculty of Worcester Polytechnic Institute in partial fulfilment of the requirements for the Bachelor of Science Degree in Mechanical Engineering and Computer Science by: Robert Duff, ME Avery Ingegneri, ME Jarred Measmer, ME Pedro de Vasconcellos Maxwell Pellerin, ME Erika Sanborn, ME Oporto, ME/CS John Williams, ME Date: May 14th 2020 Approved By: Professor David Planchard Table of Contents Table of Contents ...................................................................................................................................... 1 Abstract ......................................................................................................................................................... 4 Executive Summary ...................................................................................................................................... 5 Table of Figures ............................................................................................................................................ 6 Units .............................................................................................................................................................. 9 Units (SI and US) .......................................................................................................................................... 9 Frame .......................................................................................................................................................... 11 Powertrain ................................................................................................................................................... 19 Intake Plenum ......................................................................................................................................... 19 Exhaust .................................................................................................................................................... 25 Engine Mounts ........................................................................................................................................ 27 Shifting .................................................................................................................................................... 32 Next Steps ........................................................................................................................................... 35 Fuel Pump and Injector ........................................................................................................................... 36 Fuel Tank ................................................................................................................................................ 37 Cooling System ....................................................................................................................................... 40 Next Steps ............................................................................................................................................... 44 Intake System ...................................................................................................................................... 44 Cooling System ................................................................................................................................... 44 Brake System .............................................................................................................................................. 45 Calipers ................................................................................................................................................... 46 Master Cylinders ..................................................................................................................................... 47 Pedal Ratio .............................................................................................................................................. 47 Pedal Box, Brake Pedal, and Balance Bar .............................................................................................. 48 Rotors ...................................................................................................................................................... 51 Next Steps ............................................................................................................................................... 56 Suspension .................................................................................................................................................. 57 Tires ........................................................................................................................................................ 57 Wheels .................................................................................................................................................... 59 Linkage Layout ....................................................................................................................................... 61 Steering System ...................................................................................................................................... 63 Control Arms .......................................................................................................................................... 65 1 Rockers ................................................................................................................................................... 67 Next Steps ............................................................................................................................................... 69 Bodywork .................................................................................................................................................... 70 General Design Choices .......................................................................................................................... 70 Design ..................................................................................................................................................... 71 Nosecone ............................................................................................................................................. 71 Side Pods ............................................................................................................................................. 71 Manufacturing ......................................................................................................................................... 71 Next Steps ............................................................................................................................................... 75 Finish Nosecone Mold ........................................................................................................................ 75 Assemble Side Pod Mold(s) ................................................................................................................ 75 Vacuum bagging layup of all components .......................................................................................... 76 Fastening Panels to Frame .................................................................................................................. 76 Ergonomics ................................................................................................................................................. 77 Firewall ................................................................................................................................................... 77 Digital Sensor System ................................................................................................................................. 79 Objectives ............................................................................................................................................... 79 State of the art ......................................................................................................................................... 80 Objectives for each subsystem ................................................................................................................ 84 Conclusion & Results - Digital Sensor System..................................................................................... 102 Appendix A: SOLIDWORKS Studies ...................................................................................................... 103 Pedal Box Version 1 ............................................................................................................................. 103 Drilled Brake Rotor ............................................................................................................................... 105 Appendix B: Status of Components .......................................................................................................... 109 Intake System ........................................................................................................................................ 109 Exhaust System ..................................................................................................................................... 109 Engine Mounts ...................................................................................................................................... 109 Brake