Concurrent Engineering
- 1. ME 138: Formula SAE ChassisFinal DesignJed EscovillaJoe FiniBen LyJesse ThompsonGustavo Ortiz
- 2. Goals and Ideas 2010 ChassisTorsional Rigidity: 370 lb-ft / degreeThe Use of FEA
- 3. F-SAE 2010 Chassis: WeightWeight: Under 63 lbsThe Lighter The Faster
- 4. F-SAE 2010 Chassis: ComfortDrivers Seating Angle & Front Hoop: Increase Comfort and Ease Driver Egress
- 5. Concurrent Engineering Principles UsedDesign for ManufacturingDesign for CostDesign for Serviceability
- 6. Design for ManufacturingRedesigned frame has reduced amount of welded joints Reduced the number of tubing for the frame
- 7. Redesign of Front Hoop2009 front hoop had too many butt welded joints, these are replaced with bends.
- 8. Reduction in Frame TubingRemoved tubing from engine mounting structure
- 9. Design for CostsManufacturing Costs were reduced by :Replace welds with bending when possibleReducing number of tubes for frameMaterial CostsSteel used for frame increased but only by a small amount to make up for loss rigidity.
- 10. Design for ServiceabilityMain hoop bracing redesign for engine serviceability.
- 11. FEA Analysis and testing
- 12. Torsional RigidityWithout proper rigidity significant frame bending occurs (strain)With major flexing in the frame, clearances will be affectedFrame flex induces forces not originally intended
- 15. Race Conditions SimulationApplying loads during race conditions Most extreme case: Turning
- 16. FSAE Autocross ConditionsD7.2 Autocross Course Specifications & SpeedsD7.2.1 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).Straights: No longer than 60 m (200 feet) with hairpins at both ends (or) no longer than 45 m(150 feet) with wide turns on the ends.Constant Turns: 23 m (75 feet) to 45 m (148 feet) diameter.Hairpin Turns: Minimum of 9 m (29.5 feet) outside diameter (of the turn).Slaloms: Cones in a straight line with 7.62 m (25 feet) to 12.19 m (40 feet) spacing.Miscellaneous: Chicanes, multiple turns, decreasing radius turns, etc. The minimum track width will be 3.5 m (11.5 feet).F=20.5slugs*44ft/s^2/29.5ft = 1,331 Pounds of Force OR (66ft/s^2)/(32.2ft/s^2)=2 *Gs
- 17. COST
- 18. FSAE Cost GuidelinesCost Event – The Cost Event Rules (abbreviated)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.2. No Receipts – Since prices are standardized no receipts are required – except when requesting items be added to the table.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.
- 19. 2010 CostCost estimate for frame design consisting of 57 tubes and 114 tube ends
- 20. Material Costs:- frame weight = 63.25 lbm - standardized cost = $4.95/lbm - material cost = $313.09
- 21. 2010 CostManufacturingStandardized Costs:Tube prep = $0.75/endTube cut = $1.20/endTube weld = $1.20/endTube bend = $0.75/bend
- 22. 2010 CostManufacturing Costs - 114 welds = $136.80- 8 bends = $6.00- 114 tube preps = $85.50- 114 tube cuts = $136.80- Total = $365.10
- 23. 2010 CostMaterials Cost = $313.09Manufacturing Cost = $365.10Total = $678.19
- 24. Old VS NewCost ReductionsShorter Chassis
- 26. More bends
- 27. Reduces the number of tube ends to be notched and welded
- 28. Bending is cheaper than cutting, prepping, and welding ends2009 ChassisItem Qty Cost Tube Cuts 130 $ 156.00Tube Prep 130 97.50Tube Welds 130 156.00Bends 4 3.00Material Costs 306.90Total Cost 719.402010 ChassisItem Qty Cost Tube Cuts 114 $ 136.80Tube Prep 114 85.50Tube Welds 114 136.80Bends 8 6.00Material Costs 313.08Total Cost 678.19
- 29. Total Savings$ 41.21~5.7%Any Questions?