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A manufacturing process study for a formula style racecar chassis. Project\'s objective was to reduce manufacturing costs by simplifying certain parts of the frame while maintaining satisfactory rigidity.
ME 138: Formula SAE Chassis<br />Final Design<br />Jed Escovilla<br />Joe Fini<br />Ben Ly<br />Jesse Thompson<br />Gustavo Ortiz<br />
Goals and Ideas 2010 Chassis<br />Torsional Rigidity:<br /> 370 lb-ft / degree<br />The Use of FEA<br />
F-SAE 2010 Chassis: Weight<br />Weight: <br /> Under 63 lbs<br />The Lighter <br /> The Faster<br />
F-SAE 2010 Chassis: Comfort<br />Drivers Seating Angle & Front Hoop:<br /> Increase Comfort and Ease Driver Egress<br />
Concurrent Engineering Principles Used<br />Design for Manufacturing<br />Design for Cost<br />Design for Serviceability<br />
Design for Manufacturing<br />Redesigned frame has reduced amount of welded joints <br />Reduced the number of tubing for the frame<br />
Redesign of Front Hoop<br />2009 front hoop had too many butt welded joints, these are replaced with bends.<br />
Reduction in Frame Tubing<br />Removed tubing from engine mounting structure<br />
Design for Costs<br />Manufacturing Costs were reduced by :<br />Replace welds with bending when possible<br />Reducing number of tubes for frame<br />Material Costs<br />Steel used for frame increased but only by a small amount to make up for loss rigidity.<br />
Design for Serviceability<br />Main hoop bracing redesign for engine serviceability.<br />
Torsional Rigidity<br />Without proper rigidity significant frame bending occurs (strain)<br />With major flexing in the frame, clearances will be affected<br />Frame flex induces forces not originally intended<br />
FSAE Autocross Conditions<br />D7.2 Autocross Course Specifications & Speeds<br />D7.2.1 The following standard specifications will suggest the maximum speeds that will be encountered onthe course. Average speeds should be 40 km/hr (25 mph) to 48 km/hr (30 mph).<br />Straights: No longer than 60 m (200 feet) with hairpins at both ends (or) no longer than 45 m<br />(150 feet) with wide turns on the ends.<br />Constant Turns: 23 m (75 feet) to 45 m (148 feet) diameter.<br />Hairpin Turns: Minimum of 9 m (29.5 feet) outside diameter (of the turn).<br />Slaloms: Cones in a straight line with 7.62 m (25 feet) to 12.19 m (40 feet) spacing.<br />Miscellaneous: Chicanes, multiple turns, decreasing radius turns, etc. The minimum track width will be 3.5 m (11.5 feet).<br />F=20.5slugs*44ft/s^2/29.5ft = 1,331 Pounds of Force <br />OR (66ft/s^2)/(32.2ft/s^2)=2 *Gs<br />
FSAE Cost Guidelines<br />Cost Event – The Cost Event Rules (abbreviated)<br />1. Standardized Prices – The prices for parts, materials and processes have been standardized and the prices in the official Cost Tables must be used. If you use a part or process that’s not in the table there is a procedure for having it added. The standardized Cost Tables will be published through the FSAE website.<br />2. No Receipts – Since prices are standardized no receipts are required – except when requesting items be added to the table.<br />3. No Maximum Cost – You can spend as much as you like on your FSAE car with the understanding that your total cost is a significant factor in your Cost Event score.<br />
2010 Cost<br /><ul><li>Cost estimate for frame design consisting of 57 tubes and 114 tube ends