P 09221 Innovative Composite Parts for a Formula

P 09221: Innovative Composite Parts for a Formula SAE Racecar Team Members: David Holland Theodore Kusnierz Anthony Salvo Ryan Baldi Charles Thomas Martin Iwanowicz

Final Customer Needs • Composite Monocoque – – – • Composite Pedal Box – – – • Torsionally Stiff Lightweight Ergonomic Easily obtain complex contours High precision suspension points Test data for correlation Stiff Comfortable Lightweight Adjustable Strong Easy/quick to manufacture Composite Aero Package – – Make downforce with minimal weight gain Center of pressure below car CG Easily manufactured Easily mounted/dismounted from chassis

Engineering Specifications Chassis • Weight < 55 lbs • Resistant to cone impact @ 75 mph • Bump, accel, brake, corner loads: 3 g/1. 5 g • Production time: 14 weeks • Torsional Stiffness: 2500 lb*ft/degree • Wheelbase/Fr Track/Rear Track Width: 63”/50”/48” Undertray Lift: 30+lb @ 25 mph Weight: < 25 lb • Must mount to chassis and not interfere with suspension geometry. Pedal Box • Tube center-to-center distance = 11. 2 in • 1 in O. D. tubing • 2 g bump loading, 1. 5 g braking load • Pedal load = 200 lb • Must accommodate • 3 -pedal layout • Master cylinders • Bias bar • Adjustable • Manufacture time = < 12 hours • Weight: < 1. 5 lb

Benchmarks Chassis RIT FSAE Team F-15 Material: 4130 Fabrication Time: 15 Weeks Torsional Stiffness: 900 lb*ft/degree Weight: 456 lbs (vehicle) 74 lbs (chassis) RIT FSAE Team F-16 Material: 4130 Steel Machining Time: 13 Weeks Torsional Stiffness: 600 lb*ft/degree Weight: 426 lbs (vehicle) 65 lbs (chassis) TU Munich Material: Carbon Fiber Torsional Stiffness: 4300 lb*ft/degree Undertray TU Graz TANKIA 2007 Lift: 26 lb @ 25 mph Weight: 20 lb Pedal Box RIT FSAE Team F-16 Material: 2024 Aluminum Material Cost: $255 (est. , Mc. Master-Carr) Machining Time: 12 hours Deflection: 0. 009 in (200 lb driver input) Weight: 1. 5 lb (frame + clutch/brake tabs) Swinburne FSAE Team TS 06 Material: 7075 T 651 Aluminum Material Cost: $265 (est. , Mc. Master-Carr) Machining Time: 15 hours (est. ) Deflection: 0. 004 in (220 lb driver input) Weight: 1. 76 lb (frame)

Concept Generation Chassis Undertray Pedal Box

Plan for 12/12 Ryan Baldi Source material and machining facility for plugs. Dave Holland Obtain rough material properties. Obtain rough chassis model. Begin work in ANSYS. Aid with bell crank mounting concepts. Martin Iwanowicz Research rules compliance. Obtain loads for chassis from rigid body kinematics. Ted Kusnierz Finalize pedal box geometry and start analysis. Anthony Salvo Develop undertray geometry and start analysis. Charles Thomas Continue development of chassis geometry. Generate concept for front roll hoop mounting and bell crank mounts