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The purpose of this paper is to provide a new and improved design method for the Formula Society of Automotive Engineering (FSAE) team. There are five tasks that I accomplish in this paper: 1. I describe how the FSAE team is currently designing their car. This allows the reader to

The purpose of this paper is to provide a new and improved design method for the Formula Society of Automotive Engineering (FSAE) team. There are five tasks that I accomplish in this paper: 1. I describe how the FSAE team is currently designing their car. This allows the reader to understand where the flaws might arise in their design method. 2. I then describe the key aspects of systems engineering design. This is the backbone of the method I am proposing, and it is important to understand the key concepts so that they can be applied to the FSAE design method. 3. I discuss what is available in the literature about race car design and optimization. I describe what other FSAE teams are doing and how that differs from systems engineering design. 4. I describe what the FSAE team at Arizona State University (ASU) should do to improve their approach to race car design. I go into detail about how the systems engineering method works and how it can and should be applied to the way they design their car. 5. I then describe how the team should implement this method because the method is useless if they do not implement it into their design process. I include an interview from their brakes team leader, Colin Twist, to give an example of their current method of design and show how it can be improved with the new method. This paper provides a framework for the FSAE team to develop their new method of design that will help them accomplish their overall goal of succeeding at the national competition.
ContributorsPickrell, Trevor Charles (Author) / Trimble, Steven (Thesis director) / Middleton, James (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2015-05
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Formula SAE is a student design competition where students design and fabricate a formula-style racecar to race in a series of events against schools from around the world. It gives students of all majors the ability to use classroom theory and knowledge in a real world application. The general guidelines

Formula SAE is a student design competition where students design and fabricate a formula-style racecar to race in a series of events against schools from around the world. It gives students of all majors the ability to use classroom theory and knowledge in a real world application. The general guidelines for the prototype racecars is for the students to use four-stroke, Otto cycle piston engines with a displacement of no greater than 610cc. A 20mm air restrictor downstream the throttle limits the power of the engines to under 100 horsepower. A 178-page rulebook outlines the remaining restrictions as they apply to the various vehicle systems: vehicle dynamics, driver interface, aerodynamics, and engine. Vehicle dynamics is simply the study of the forces which affect wheeled vehicles in motion. Its primary components are the chassis and suspension system. Driver interface controls everything that the driver interacts with including steering wheel, seat, pedals, and shifter. Aerodynamics refers to the outside skin of the vehicle which controls the amount of drag and downforce on the vehicle. Finally, the engine consists of the air intake, engine block, cooling system, and the exhaust. The exhaust is one of the most important pieces of an engine that is often overlooked in racecar design. The purpose of the exhaust is to control the removal of the combusted air-fuel mixture from the engine cylinders. The exhaust as well as the intake is important because they govern the flow into and out of the engine's cylinders (Heywood 231). They are especially important in racecar design because they have a great impact on the power produced by an engine. The higher the airflow through the cylinders, the larger amount of fuel that can be burned and consequently, the greater amount of power the engine can produce. In the exhaust system, higher airflow is governed by several factors. A good exhaust design gives and engine a higher volumetric efficiency through the exhaust scavenging effect. Volumetric efficiency is also affected by frictional losses. In addition, the system should ideally be lightweight, and easily manufacturable. Arizona State University's Formula SAE racecar uses a Honda F4i Engine from a CBR 600 motorcycle. It is a four cylinder Otto cycle engine with a 600cc displacement. An ideal or tuned exhaust system for this car would maximize the negative gauge pressure during valve overlap at the ideal operating rpm. Based on the typical track layout for the Formula SAE design series, an ideal exhaust system would be optimized for 7500 rpm and work well in the range
ContributorsButterfield, Brandon Michael (Author) / Huang, Huei-Ping (Thesis director) / Trimble, Steven (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Materials Science and Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-05