ODU Formula SAE
Progress Report II
4/2/2013
Introduction
The ODU FSAE team has made significant progress towards completing the 2013 car. On top of participating in several fundraisers, the car is close to being complete. Only a few small components are left missing to have the car rolling with fully operational suspension. This will propel the rest of the car into full completion.
Aerodynamics
Analysis was completed on the flat side panels and underbody tray to verify that when secured to the frame the panels could withstand a 100 lbf impact without breaking. The newly designed panels are approximately 69% lighter than last year's panels while maintaining equivalent strength. This reduction of weight will prove beneficial during the endurance race, and fuel efficiency competition.
The nose cone mold was by replicating the nose section of the frame with plywood as if it were split vertically down the center. The plywood frames were filled with expanding foam and then carved down to the desired shape of the nose cone. One of the molds is complete and the other side is one day of carving from being complete. With the nose cone complete, installation of the body will begin. Tabs will have to be fabricated to allow the panels to be riveted and dzus fastened to the frame. Once body panels are assembled the final fit and finish with paint will be completed.
Powertrain
The fuel tank carriage has been fabricated and is in the process of being assembled. The carriage has steel straps that are tightened over the tank to hold it in place, which are fifty percent complete. The tank will be raised in order to allow the fuel pump to be placed under it and the tank to remain inside of the chassis. The actual tank still has several incomplete tasks. These include modifying the baffles, finishing the top of the tank, rollover check valve and the fuel inlet. After the tank is complete, it will be insulated to protect it from the heat of the exhaust and it will provide some vibration damping.
The wiring harness is 80% complete and only waiting for a few small components are missing. The exhaust system is fully complete and ready to be assembled onto the car as soon as the chassis welding is complete. The rear differential is fully mounted and now includes the rear braking system. This gives the brake system fully operational capability while still allowing the rear drive axles to perform at optimum level.
Chassis
The Chassis team has been steadily approaching the frame’s completion. Only the pedal assembly, brake mounts, shifting components, and full frame welding needs to be completed before the vehicle can be placed onto the ground. The upright brackets, steering arms, and the finished rotors are to be received from L and W on 4/2/13. The design of these and every other component of the frame has been focused on creating it stronger and lighter than the 2012 FSAE car.
The pedal assembly includes a brake, throttle, and clutch pedal. The brake pedal was designed to have a factor of safety of approximately 2.5, also the throttle and clutch pedals have a safety factor of approximately 1.8. Each pedal is machined from 6061 aluminum alloy. In order to place the car on the ground the frame needs to be fully welded; this will be completed by 4/8/13. Once these components are attached onto the car, the rolling chassis will be complete.