Differential for Formula SAE Race Car Shivana Mahes Uber Mantovani Alessandro Tasca Differential for Formula SAE Race Car EML4551 Ethics and Design Project Organization Team 09
SUMMARY Problem statement Project description Motivation and goals Division of Responsibilities Project Timeline Goals Design Considerations Design Alternatives Standards Global Learning Conclusion Questions
PROBLEM STATEMENT Design differential and components for the 2016 FSAE competition Components include housing, mounts, sprocket Photo credit: audi-technology-portal.de
MOTIVATION AND GOALS Motivation FSAE is a prestigious global competition Top engineers attend and judge entries Goals Optimize differential for FIU’s car Optimize power transfer Photo credit: torsen.com
DIVISION OF RESPONSIBILTIES Shivana Mahes Calculation and design of housing and spacers, Solidworks modeling and simulations, written documents Uber Mantovani Calculation and design of sprocket, springs, and friction plates, Solidworks modeling and simulations Alessandro Tasca Calculation and design of gears, prototyping, and manufacturing
PROJECT TIMELINE
GOALS Reduce weight from current differential by 15% Maintain current torque bias ratio of 4:1 Photo credit: torsen.info
DESIGN CONSTRAINTS 2016 FSAE rules 45° tilt test-differential cannot leak Withstand engine specifications Location and size of sprocket Safety and reliability Dimension of current drive axle shafts and CV joint angle Costs
DESIGN CONSIDERATION Location of differential Engine development Interchangeable sprocket
DESIGN ALTERNATIVE 1 Alternative 1 Differential using gears only Simple design Utilizes only mechanical parts Photo credit: blog.keyeslexus.com
DESIGN ALTERNATIVE 2 Alternative 2 Differential using gears and friction plates Added weight from friction plates is negligible over alternative 1 Friction plates can wear out Photo credit: italiaspeed.com
DESIGN ALTERNATIVE 3 Alternative 3 Differential using gears and spring-loaded friction plates Capable of achieving highest torque bias ratio of all 3 alternatives More complex than all 3 alternatives Increases cost of manufacturing and maintenance Photo credit: torsen.info
DESIGN ALTERNATIVE 3 Photo credit: torsen.info
SURVEY OF STANDARDS American Society of Testing and Materials Specific standards to be used depend on material selected American Gear Manufacturers’ Association Standards apply to gears, couplings, and power transmission components
SURVEY OF STANDARDS Society of Automotive Engineers Bolts and viscosity of lubricants
GLOBAL LEARNING Design for manufacturability in various parts of the globe Use of universal units (SI/US) Manual in multiple languages Cost analysis for different regions in different currencies
CONCLUSION Design, manufacture, and assemble differential for 2016 FIU Formula SAE car Optimize drivetrain Reduce weight Maintain current TBR
QUESTIONS