Rolling Chassis Team Todd Anderson Matt Blackwood David Hovater Josh Smith Jessica Yoho

Overview Formula SAE at a Glance Project Summary  Frame  Suspension  Brakes  Steering  Seat  Uprights Building Parts  Lathe  Mill  Large Band Saw  Small Band Saw  Composites Important Dates

Formula SAE Competition One of the largest Collegiate competitions Design, build, and compete with small Formula style cars 140 Universities from around the world compete in static and dynamic events Increase awareness for The University of Alabama Covers many aspects of Engineering Competition Date: 5/18/2005 – 5/22/2005

Formula SAE 0-60 in under 4 seconds Can corner up to 1.5 g’s Weighs around 500lbs 70 Hp Engine

Project Statement Design, build, and test a rolling chassis for integration with the 2005 UA Formula SAE car design.

2005 Car at a Glance

66” Wheelbase 48/46” Front Rear Track Seating Position under the Main Roll Hoop Two Pedals Pull Rod Suspension Semi Stressed Engine

Frame at a Glance

Frame Objectives Reduce Weight  Less than 60lbs total weight for the Frame  Use of Thinner Tubing Increased Driver Room Increase Torsional Resistance Reduce Complexity  Integrate Subsystems into Frame  Use of Square Tubing  Partially Stressed Engine  Easier to Build 4130 Spaceframe

Frame Analysis (Front) FEA Analysis in ANSYS Max Deflection: <0.08in Max Stress <31ksi

Suspension at a Glance Double A-arms Low Roll Center Pull Rod Vanilla RC Bicycle Shocks Anti-Sway Bar Use of Spherical Bearings

A-arm Attachment to Frame Shims 1/4” bolt Aluminum Bracket Spherical bearing & housing A-arm Front View

Spherical Bearings Mis-Alignment Angle of 24º Will Be in Housing held in place by a snap ring

Front A-arms Analysis FEA ANSYS Results  Loaded to Simulate Braking and Cornering Max Deflection <0.05” Max Stress <22ksi

Brakes At a Glance 3 Disc Setup  2 Outboard Brakes in Front  1 Inboard in Rear 9” Diameter Rotors Dual Piston Calipers Left Foot Brake setup (Only two Pedals) Balancing Bar

Brakes Wilwood PS-1 Calipers  Dual 1.12 inch pistons 9”Custom Rotors Dual master cylinders  Balancing bar used to adjust bias PS-1 Caliper Dual MC Balance bar

Steering Located under Driver’s legs Ackerman Geometry 12 ft Turning Radius Minimal Bump Steer Two Universal Joints to Route Steering Linkage

Steering Rack Track Travel: 3” Weighs 1.96 lbs Rack Length is 8.5” Turns Lock to Lock Jr. Dragster Steering Rack From Chassis Shop

Seat at a Glance Carbon Kevlar Composite Reclined 30º from the Vertical Legs Elevated 4” Lateral Support

Front Uprights

Front Upright Brake Caliper Bracket moved to integrate into Steering Attachment Steel Construction opposed to Aluminum  Similar Weight  Reduced Cost  Easier to Make  Endurance Rotor Mount integrated into Wheel Studs Smaller Spindle and Inboard Bearing to take Advantage of Strength of Steel

Front Upright FEA Analysis ANSYS  Max Deflection <0.003”  Max Stress < 16ksi Weighs Approximately 2.75lb with Axle and Brake Bracket

Rear Uprights at a Glance Aluminum 6061-T6 CNC Design Minimal Deflection Lightweight Taylor Racing Stub Axle

Rear Uprights Overall Dimensions Constraints / Loading Conditions Maximum Deflection is 0.002” Maximum Stress is 3500 psi

Stub Axle Stub Axle Assembly will be changed to same model used in 2004 Car  More Expensive but can be covered with new Funds  Much Stronger, more Proven, and Lighter  Manufactured by Taylor Racing

Building Plans Construction of Rolling Chassis needs to be completed by December 16 th 489 Currently occupying Projects Building Starting November 11 th 1-4pm Weekday Afternoons Wednesday November 24 th – All day

Lathe Spindle Housings for Spherical Bearings Engine Mounts

Mill Frame Members Pieces for Jig Table Assembly Jig for Front Upright A-arms Brake Rotor

Large Band Saw Frame Members Front Upright Pieces A-arms

Small Band Saw A-arm Attachments Front Upright

TIG Welder Frame Frame Jig Table Front Uprights A-arms A-arm mounts to Frame

Other Bench Grinder  A-arm Attachments  Front Upright Chop Saw  Frame Members

Composite After Step 1: Sand seat to proper dimensions Step 2: Apply Bondo to the entire seat Let seat dry for 24 hours Step 3: Sand down seat to a smooth finish with fine grit sandpaper Step 4: Cut several sheets of Carbon Kevlar fabric to the specified dimensions. Step 5: Lay one sheet of fabric vertically on the seat mold and apply resin. Allow to dry. Step 6: Lay another sheet of fabric horizontally on the seat mold and apply resin. Allow to dry. Repeat as needed. Step 7: Discard foam mold. Before

Important Dates November:  7 th Last Autocross of the year in Birmingham  17 th Engine Mounted to Dyno  24 th Drivetrain Coupling Completed Composite Process Build Date in Projects Building December:  4 th Stock Engine Running  16 th Rolling Chassis Completed January:  21 st Running Engine With Restrictor Pedal Construction March:  18 th Driving

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