P09221: Innovative Composite Parts for a Formula SAE Racecar

P09221: Innovative Composite Parts for a Formula SAE Racecar

P09221: 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 < 55lbs Resistant to cone impact @ 75mph Bump, accel, brake, corner loads: 3g/1.5g/1.5g Production time: 14 weeks Torsional Stiffness: 2500lb*ft/degree Wheelbase/Fr Track/Rear Track Width: 63/50/48 Undertray Lift: 30+lb @ 25mph Weight: < 25lb Must mount to chassis and not interfere with suspension geometry. Pedal Box Tube center-to-center distance = 11.2in 1in O.D. tubing 2g bump loading, 1.5g braking load Pedal load = 200lb Must accommodate 3-pedal layout Master cylinders Bias bar

Adjustable Manufacture time = < 12 hours Weight: < 1.5lb Benchmarks Chassis RIT FSAE Team F-15 Material: 4130 Fabrication Time: 15 Weeks Torsional Stiffness: 900lb*ft/degree Weight: 456lbs (vehicle) 74lbs (chassis) RIT FSAE Team F-16 Material: 4130 Steel Machining Time: 13 Weeks Torsional Stiffness: 600lb*ft/degree Weight: 426lbs (vehicle) 65lbs (chassis) TU Munich Material: Carbon Fiber Torsional Stiffness: 4300lb*ft/degree Undertray TU Graz TANKIA 2007 Lift: 26lb @ 25mph Weight: 20lb Pedal Box

RIT FSAE Team F-16 Material: 2024 Aluminum Material Cost: $255 (est., McMaster-Carr) Machining Time: 12 hours Deflection: 0.009in (200lb driver input) Weight: 1.5lb (frame + clutch/brake tabs) Swinburne FSAE Team TS06 Material: 7075 T651 Aluminum Material Cost: $265 (est., McMaster-Carr) Machining Time: 15 hours (est.) Deflection: 0.004in (220lb driver input) Weight: 1.76lb (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

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