-2016

FALL 2015 FSAE Composites Proposal

IRA Fulton School of Engineering

September 5, 2015

Arizona State University

Faculty Advisor: Dr. Steven TrimbleProject Manager: Curtis Swift

Contents

Executive Summary.................................................................................................................................................. 3

Introduction............................................................................................................................................................... 3

Validity statement..................................................................................................................................................... 3

Literature Survey...................................................................................................................................................... 3

Introduction........................................................................................................................................................... 3

Rules..................................................................................................................................................................... 4

Project Description................................................................................................................................................... 4

Project Organization................................................................................................................................................. 5

Design Basis............................................................................................................................................................. 5

Project Deliverables.................................................................................................................................................. 6

Action Item List......................................................................................................................................................... 6

Timeline.................................................................................................................................................................... 7

Resources................................................................................................................................................................ 8

Appendix A: Resume................................................................................................................................................ 9

Appendix B: References......................................................................................................................................... 10

Appendix C: Project Specifications......................................................................................................................... 10

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Executive Summary

Every year the Society of Automotive Engineers (SAE) organizes a Formula SAE (FSAE) student design competition in which groups of student engineers design and manufacture single seat open wheel vehicles. In addition to the finished product, students must also provide technical drawing specifications and explanatory text near project completion. The goal of the project is to redesign the car seat subsystem in order to simplify the existing design, decrease manufacturing time, decrease overall weight of the finished vehicle, improve the fuel economy, and improve its performance. In order to test all the subsystems the project will be completed near the end of Spring 2015. The expected cost of the project, including all of the materials and components, will be no more than $300.

Introduction

The main goal of creating a simplified FSAE racecar design is meant to allow for student engineers to, as a team, design and manufacture a Formula SAE Racing Car. The competition is meant to give students an opportunity to deal with real world engineering experience and hands on manufacturing. Given the time constraint teams must drastically reduce the time required to design, build, and test the vehicle. With a much simpler design, the cost of manufacture will be decreased due to reduced building materials and will minimize the weight of the finished product, which is an underestimated attribute of a racecar. The most weight will be shed from replacing materials with composites all while making sure not to compromise the rigidity of the frame and ultimately the safety of the driver.

The goals listed above will be completed in the final product all while conforming to the updated Society of Automotive Engineers Rules and Guidelines for the year of 2015.

Validity statement

This proposal is a preliminary proposal and the members of the Subsystem FSAE team reserve the right to review it and determine if any modification is needed.

Literature Survey

Introduction

Every year the Society of Automotive Engineers (SAE) sponsors many vehicle based competitions open to collegiate universities across the globe. One of the competitions is called Formula SAE (FSAE). In this competition a group of student engineers design single seat open-wheel vehicles capable of enduring rigorous racing events. These events include a timed autocross race, endurance race, skid pad test, and acceleration test all of which will be explained in more detail later in this report.

The Society of Automotive Engineers requires a very strict technical set of rules that the vehicle must adhere to. These rules are put in place to control the specifications to which the vehicle can be built, and to ensure the safety of everyone participating in the competitions. A very thorough inspection is conducted on all vehicles before they are allowed to compete in any event. The safety inspection is performed first to ensure the chassis and components of the vehicle are built to the minimum requirements and will protect the driver in the event of a collision. The safety gear and harness are also inspected to ensure driver protection. Several other inspections are performed before the vehicle is allowed to do the dynamic technical inspections which include sound test, braking test, and tilt test.

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Once the vehicle is deemed safe for competition the dynamic racing events commence. These aforementioned events are conducted with the goal of completing them with the quickest time. The quicker the time that is taken to complete the event the more points are given to your team and the higher you will place. The dynamic events accumulate about 1/3 of the overall competition points, the endurance race being the most influential out of all of them.

Rules

The overall design objectives of the competition according to the 2015 FSAE rulebook are as follows:

A1.2 Vehicle Design Objectives For the purpose of the Formula SAE competition, teams are to assume that they work for a design firm that is designing, fabricating, testing and demonstrating a prototype vehicle for the non-professional, weekend competition market.

A1.2.1 The vehicle should have very high performance in terms of acceleration, braking and handling and be sufficiently durable to successfully complete all the events described in the Formula SAE Rules and held at the Formula SAE competitions.

A1.2.2 The vehicle must accommodate drivers whose stature ranges from 5th percentile female to 95th percentile male and must satisfy the requirements of the Formula SAE Rules.

A1.2.3 Additional design factors to be considered include: aesthetics, cost, ergonomics, maintainability, manufacturability, and reliability.

A1.2.4 Once the vehicle has been completed and tested, your design firm will attempt to “sell” the design to a “corporation” that is considering the production of a competition vehicle. The challenge to the design team is to develop a prototype car that best meets the FSAE vehicle design goals and which can be profitably marketed.

A1.2.5 Each design will be judged and evaluated against other competing designs to determine the best overall car [12].

Project Description

The main part of this project is the driver seat and cockpit. Most of the subsystems are directly in contact with the cockpit and this is where the driver interacts with all the subsystems. The cockpit area is where the critical components needed for proper vehicle operation in racing vehicles. Racing vehicles require much stiffer and stronger chassis and suspension as driver comfort is not a concern and vehicle performance is the main goals. This project looks aims to protect the driver in the event of a collision, while maintaining the low weight to strength ratio, and improve overall rider comfort.

The overall project including sub-system interactions is illustrated in Figure 1:

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Figure 1.

Project Organization

Using the ergonomics set up that was created to improve and simulate the subsystems of the vehicle, a female piece of the seat can be made.

Design Basis

The basis of design for the composite seat is based on the Fall 2015 FSAE projects shown below in Figure 2 and Figure 3.

Figure 2.

Figure 2 shows the ergonomic set that will be used to model the seat and simulate the comfort of the driver.

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Figure 3.

Figure 3 shows the final chassis set up that was used to create the ergonomic assembly.

Project Deliverables

CAD renderings of all items FEA analysis (mechanical characteristics) Validations for all design changes to be implemented Testing to show design outcomes Finished Seat by Dec 2015 Actual implementation on Spring 2015 FSAE vehicle

Action Item List

SQUAD:Persons: Field:

Marco A. Chavez MAC MEAdrian Quijada AQ MEDavid Solis DS MENestor Obeso NO MECesar Yanayaco CY MEVarun Reddy VR ME

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# Action Persons Assigned Date

Due % Completion

New Due Date

Concern

1 Research Costs MAC 8/31/15 9/4/15 100% N/A N/A2 Write up Proposal MAC 8/31/15 9/4/15 100% N/A N/A3 Turn in Proposal MAC 8/31/15 9/4/15 100% N/A N/A4 Design Seat

(SolidWorks)TBD TBD TBD TBD N/A N/A

5 ANSYS (Test) TBD TBD TBD TBD N/A N/A6 Order Parts TBD TBD TBD TBD N/A N/A7 Feedback on seat TBD TBD TBD TBD N/A N/A8 Cast Female piece Foam TBD TBD TBD TBD N/A N/A9 Sand Female piece Foam TBD TBD TBD TBD N/A N/A10 Finalize female piece

foamTBD TBD TBD TBD N/A N/A

11 Cast Male Plug TBD TBD TBD TBD N/A N/A12 Finalize Male Plug TBD TBD TBD TBD N/A N/A13 Cast Final Piece TBD TBD TBD TBD N/A N/A

Timeline

Chronological order

Action Assigned Date

1 Research Costs 8/31/152 Write up Proposal 8/31/153 Turn in Proposal 8/31/154 Design Seat (SolidWorks) TBD5 ANSYS (Test) TBD6 Order Parts TBD7 Feedback on seat TBD8 Cast Female piece Foam TBD9 Sand Female piece Foam TBD10 Finalize female piece foam TBD11 Cast Male Plug TBD12 Finalize Male Plug TBD13 Cast Final Piece TBD

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Resources

The Formula SAE team has its own shop and access to TechShop; hence, the manufacture of the final product will not require many more resources. CNC’s, vacuum forming and all other fabrication processes will be done in house. It is also notable that the arrangements have been made for anything that will need to be manufactured at another location.

Item #

Item Description QuantityPrice per

component ($)Total ($)

1 Disposable Gloves (Box of 100) 1 7.00 7.002 Carbon fiber sheet (m^2) Twill About 4 35.00 140.003 Carbon fiber sheet (m^2) Twill 12 oz. About 2 40.00 80.004 Disposable Face mask (Box of 30) 1 10.00 10.005 Sandpaper 2000 grit (10 Pack) 1 5.00 5.006 Sandpaper 1000 grit (10 Pack) 1 5.00 5.007 Sandpaper 100 grit (10 Pack) 1 5.00 5.008 Mylar Tape (Clear-Brown) 2 2.00 4.009 Wax (12oz) 1 10.00 10.0010 Putty (10 oz.) 1 5.00 5.0011 Measuring tools Multiple On hand 0.0012 Cardboard/Paper (Clean up) Multiple On hand 0.0013 Clear coat gel (1/2 gal) 1 On hand 0.0014 PVA release agent (1 L) 1 On hand 0.0015 Vacuum pump and ports 1 On hand 0.0016 Safety Glasses 10 On hand 0.0017 Spatula About 15 On hand 0.0018 Bondo (Gal) 1 On hand 0.0019 2 Density - Polyurethane 2 Part Expanding Foam (1/2 gal) 1 On hand 0.0020 Fiberglass sheet (m^2) Stand mat 12 oz. 3 On hand 0.0021 Fiberglass Resin (Gal) 1 On hand 0.0022 Fiberglass (Hardener) oz. 24 On hand 0.0023 Fiberglass sheet (m^2) Woven twill 12 oz. 10 On hand 0.0024 Epoxy (Gal) 1 On hand 0.0025 Epoxy (Hardener) (oz.) 24 On hand 0.0026 TechShop On hand On hand 0.0027 Computers On hand On hand 0.0028 Solidworks Modeling Software On hand On hand 0.0029 Matlab On hand On hand 0.0030 Formula SAE shop On hand On hand 0.00

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3132

TOTAL 271.00

Appendix A: ResumeMarco A. Chavez7351 W Meadowbrook Ave. Phoenix, AZ 85033C: 623 698 7477 E: marco.a.chavez@gmail.com

ObjectiveHighly motivated mechanical engineer student seeking Fall internship to grow and apply engineering skills.

Experience/

Activities

Disassembly/Assembly Technician- Summer Intern June 2015 – August 2015 Led, modified and implemented disassembly outline that maximized efficiency, safety, and reduced

overall project time by 75%. Exceeded daily production goals of getting charging units software and hardware updated,

packaged and stored. Troubleshoot hardware and software, tested different electrical and mechanical components,

organized sub systems to facilitate production, disassembly and assembly line.

Residential and Commercial PaintingStaffing Manager June 2007 – Present

Manage overall paint business including referrals, bids, cash management, supplier inventory, finances and customer service.

Supervise employees including work schedules, quality of work, training and coaching. Design and visualize end product to influence customers toward right choice.

Sept. 2014– March 2015 Designed/developed dashboard, hood scoop and nose cone. Fabricated composite dashboard under budget. Utilized carbon fiber, fiberglass, resin, bondo, two-part polyutheleane foam and composite

materials.

Research and Design Fall 2012 – Present Research and Development of composite materials for use in vehicle. Designed and developed different arrangements of composite materials for specific tensile and

lateral strength goals. Fabricated sample product out of designed composite materials. Created a monocoque frame on Solid Works for composite vehicle.

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Education/ Awards

Arizona State University Dec 2016Bachelor of Science in Mechanical Engineering, GPA 3.19/4.0

Estrella Mountain Community College May 2013Associates in Science, GPA 3.663/4.0 -EMCC Presidential Scholar Recipient Fall 2010-Spring 2012 -STEM Scholarship Recipient Fall 2010-Spring 2013 -Emerging Scholars Scholarship Recipient Fall 2011-Spring 2012 -EMCC Collegiate Scholar Recipient Fall 2012-Spring 2013

Skills Language: Fluent in Spanish Proficient in Microsoft Word, Power Point, Excel, SolidWorks, and MATLAB Introductory experience in JAVA Great organization skills Excellent communication skills Detail oriented

Appendix B: References

[1] Edmondson, C. (2011). Fast car physics / Chuck Edmondson. Baltimore, Md. : Johns Hopkins University Press, 2011.

[2] Staniforth, A. (1999). Competition car suspension : design, construction, tuning / Allan Staniforth. Newbury Park, CA : Haynes North America, 1999.

[3] Milliken, William F., and Douglas L. Milliken. Race Car Vehicle Dynamics. Warrendale: SAE, 1995. Print.

[4] Adams, Herb. Chassis Engineering. New York: The Berkley Publishing Group, 1993. Print.

[5] Bolles, Bob. Advanced Race Car Chassis Technology. New York: The Penguin Group, 2010. Print.

[6] Isaac-Lowry, Jacob. "Suspension Design: Types of Suspensions." AutomotiveArticles. N.p., n.d. Web. 5 Oct 2013. <file:///H:/Suspension Design Types of Suspensions.htm (Source1).htm>.

[7] 2014 formula sae rules. (n.d.). Retrieved from http://students.sae.org/cds/formulaseries/rules/2014_fsae_rules.pdf

Appendix C: Project Specifications

Weight under 5 lbsSeat

Type Race SeatMaterial Carbon Fiber-Fiberglass composite

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