1. ODU Formula SAE
MAE 435 Midterm Report

2. Formula SAE
The Formula SAE competition challenges teams of university undergraduate and graduate students to conceive, design, fabricate, develop and compete with small, formula style, vehicles.

3. Competition Static Event Points: Dynamic Event Points:
Presentation (75)
Engineering Design (150)
Cost Analysis (100)
Dynamic Event Points:
Acceleration (75)
Skid-Pad (50)
Autocross (150)
Efficiency (100)
Endurance (300)

4. Our Team MATTHEW SANTJER BJORN MALMFELDT CHRIS SAVEDGE
MICHAEL TERLESKY
ROBERT SLADE
RICHARD JONAS
GEORGE KOUTROS
JASON LENHARDT
JOHN PRESGRAVES
DANIEL SMITH
RYAN TETER
NICHOLAS GARNER

5. Suspension Suspension has been designed in SolidWorks.
Suspension Geometry was identified using Optimum Kinematics.

6. Suspension Shocks, pushrods, and rockers have been installed
Camber, caster, and toe has been properly set
The rockers were designed for ideal motion ratio and linear spring rate

7. Differential Analysis
The differential has been designed and fabricated.
SolidWorks analysis will be conducted on the existing design.

8. Intake The intake has been fabricated and installed.
Currently we are analyzing different restrictors designs in SolidWorks
The team will 3D print several restrictors and test on the flow bench.

9. The headers has been installed on the engine and leak tested.
Exhaust
The headers has been installed on the engine and leak tested.
The firewall is being designed to insure the seat and fuel tank are not subject to heat produced by exhaust system.

10. Body panels are being fabricated using fiberglass.
Aerodynamics
Body panels are being fabricated using fiberglass.
Analysis will be conducted with Fluent software to calculate maximum downforce generated by diffuser.

11. The calipers have been mounted to the uprights.
Brakes
The calipers have been mounted to the uprights.
The pedals have been fabricated & installed and master cylinders mounted on the frame.
Hydraulic pressure has been adjusted and a thermal analysis is being conducted on the system.

12. Force analysis for the pneumatic shifting system has been conducted.
Control System
The manual shifting lever has been fabricated and installed on the car.
Force analysis for the pneumatic shifting system has been conducted.
MXL Strada is awaiting purchase and will be electrically mated with ECU upon arrival.

13. Analysis has been conducted on each pedal using SolidWorks
Pedal Assembly
The pedal setup is a three pedal assembly with a clutch, brake, gas arrangement.
Analysis has been conducted on each pedal using SolidWorks

14. Progress - Chassis Design
The chassis design and fabrication has been completed.
Our team started by fabricated the current table to be level in all planes and mounting holding brackets for the front, console, driver, and rear hoops.
The structural members have been fabricated using hollow steel using the following types:
1”x1”x0.049” Square
1”x0.095” Round
1”x0.065” Round
1”x0.049” Round

15. Progress - Parts
Metal Concepts Inc. has fabricated parts for the pedals, differential, intake, and suspension.

16. Progress - Steering
The steering rack has been aligned in plane with uprights for smooth wheel movement.
The steering rods have been fabricated and connected to the steering knuckles on the uprights.
The steering wheel has been located and mounted for best possible driver ergonomics.

17. Progress - Uprights
The uprights have been designed, fabricated and installed. The upper and lower A-Arms and steering have been connected and tested.

19. Questions?