NEM4420: Mechanical Design Project

Formula SAE Vehicle Design Project (Capstone Engineering Design Project)

Victoria University Motorsport (VUM) has designed a chassis for its next entry into the Formula SAE (F-
SAE) competition. The chassis has been designed in accordance with the 2017-18 F-SAE and Confederation
of Australian MotorSport (CAMS) rules. The configuration has been developed to maximise torsional
stiffness and to minimise overall mass. The chassis, known as 2017-R3, is shown in Fig. 1.

A great deal of work has gone into the design of the chassis; however, limited attention has been given to the
suspension, the aerodynamics, driver ergonomics or the powertrain.

Figure 1: VUM chassis 2017-R3 Part originally designed by Dale Nash and Jayden Steel with modifications
by Aaron Trist.

The purpose of this subject is for you all to act as one team (yes the whole class) to design the missing
components of the car. In designing the car you must maintain the original chassis design as it is currently
being built. The final design must comply (unless negotiated with the client) with the specifications in table 1
and should use the current wheels and tyre size (see VU Collaborate for the SolidWorks model). In addition
to the specifications provided in table 1, all designs must comply with the latest F-SAE rules.
 Table 1: Desired design specifications

Suspension and Steering

Wheelbase Must not exceed 1835 mm (check F-SAE rules for
minimum value). Target 1645 mm
Track Front Approx. 1100 mm at wheel centreline (check F-SAE
rules for minimum value).
Track Rear Approx. 1043 mm at wheel centreline (check F-SAE
rules for minimum value).
Track change (due to bump and roll motion) Minimise.
Anti-dive Up to 20%. Adjustability desirable.
Anti-squat Up to 10%. Adjustability desirable.
Rear roll centre height (RRCH) FRCH < RRCH < 45 mm (adjustable is desired).
Target 35 mm
Front roll centre height (FRCH) 0.5 x RRCH < FRCH < 0.75 x RRCH (adjustable is
desired). Target 25 mm
Relative vertical movement between RRCH and Minimise. Ensure RRCH is always higher than
FRCH during bump and roll FRCH.
Travel (vertical) Target 25.4 mm. Must allow for 25 mm bump travel.
Do not allow spring to become unloaded at full droop
(i.e. depends on spring rate).
Camber (front and rear) Adjustable between 0 and -4. Must remain less than
0 for full range of bump motion.
Camber gain (front) Loaded wheel must remain upright (from a static
setting of -1 to -2) for 2 of chassis roll.
Start with an initial value of 0.8-1/inch (bump)
negative camber gain.
Camber gain (rear) Rear wheel camber must not exceed -2 for full range
of vertical wheel motion. Loaded wheel must remain
as upright as possible for up to 2 of chassis roll.
Start with an initial value of 0.8-1/inch (bump)
negative camber gain.
Scrub radius 15 mm to 20 mm.
Caster (front) Adjustable between 0 and 4.
Caster (rear) 0.
Toe (front and rear) Adjustable. Target 0 5 mm.
Steering ratio Set to allow for no more than steering wheel turn
during tightest race corner (see FSAE documentation
for tightest corner).
Ackermann Adjustable (front steer and near to parallel, i.e. 0
Ackermann). Consider tyre slip.
Spring/damper activation method Bellcrank (either push rod)
Installation ratio Set to maximise damper travel. Must be rising rate in
bump (approx. 5% per inch front and 2.5% per inch
rear)
Ride frequency Approx. 3 Hz undamped (front higher than rear see
OptimumG recommendations).
Roll gradient Target 0.8 to 1.2 deg/g. May need anti-roll bars.
Adjustability desirable.
Total lateral load transfer 5% more than weight distribution at front.
 Table 1: Desired design specifications continued

Aerodynamics
Speed range 0-100 km/hr (average 70 km/hr).
Front to rear downforce bias Centre of pressure must match centre of gravity.
Assume 45% front 55% rear for initial designs.
Twin side pods (dual radiators, approx.. 330 mm tall -
and 150 mm wide)
Minimum ground clearance 30 mm.
Materials (body, wings and diffuser) Fibreglass (thin aluminium sheeting allowed in small
quantities).
Powertrain
Speed range 0-100 km/hr (average 70 km/hr).
Gears in use 2nd and 3rd (higher if required, but not 1st).
Final drive ratio Maximise acceleration.
Engine performance Dyno results provided as requested

As identified in the unit guide, your assessment will be broken down as follows (due dates are in the unit
guide):

Item Description Weighting

Portfolio Comprised of weekly updates of the design process 40%

and demonstration of the skills developed team
assessment

Report 1 Interim design report team assessment 10%

Report 2 Final design report team assessment 50%

Portfolio: A full breakdown of the portfolio submissions is given in the weekly schedule in the unit guide.
Instructions will be provided in class and via email as required (most things I hope are obvious based on the
unit guide description, please let me know if they are not).

Report 1: This is a preliminary/interim report. Its purpose is not only to measure your productivity, but is
also a chance for you to receive feedback on your development of designs. The report should contain:

Literature search results including what design techniques you will follow, methods for determining
specific dimensions and a brief summary of associated F-SAE rules and compliance. It does not
mean you need a history or a summary of all other peoples work.
Preliminary analysis results
Professionally presented SolidWorks drawings of preliminary design concept (should include an
isometric and dimensioned orthogonal drawings prepared in accordance with AS 1100.101 and AS
1100.201)
Specifications table for preliminary design
Scope for further development, including what you need to know from other groups.

The report should be thorough, but concise. It is meant as a design report which clearly identifies the
constraints, design goals, analysis methods and results, the preliminary design geometry and specifications
and scope for further work.
Teams that include superfluous information will be penalised. Large amounts of data, or material not
developed by the students (eg. F-SAE rules), should be included in an appendix, not the body of the report
(make sure you make reference to all appendix data in the body of the report).

All figures and tables must be described and referred to in text.

Referencing of literature must be consistent and complete (in text and reference list).

Report 2: Your report 2 is a continuation of report 1. The submission should be adjusted in accordance with
all feedback provided and to have a stronger emphasis on the final analysis results, final design drawings
(which need to be detailed and prepared in accordance with the standards referred to previously) and the final
design specifications. The report must address all design changes deemed as necessary during the week 9
presentations.

Attendance: You must attend all lectures and tutorials, this is an interactive class and you must be available
to speak with your lecturer (as client and mentor) and the other design groups. Your assessment will be
influenced by your interaction with other groups and your ability to meet their requests.
Possible Projects (projects will be limited based on class size, suspension projects are a priority):

Suspension and steering team (6 students):

1. Front suspension design, CAD modelling and analysis of a-arms, push rods, mounts and bellcranks
and mounting points. Must aim to use 2014 bellcrank centres (files provided at request). (2 students)

2. Rear suspension design, all geometry and CAD modelling of a-arms, push rods and bellcranks and
mounting points. Must aim to use 2014 bellcrank centres (files provided at request). (2 students)

3. Uprights must conform to suspension team requirements. Start initial analysis based on 2016 designs
with improvements to bearing pre-load adjustment and overall mass. Responsible for Ackermann,
brake selection and mounting, steering system (rack mounting, steering ratio, etc.) and hub design
(must collaborate with powertrain team for hub design). (2 students)

Aerodynamics (3-4 students). All designs must include mounting methods

1. Nose cone (1 student)

2. Front and rear wing, responsible for overall aerodynamic balance (1-2 students)

3. Diffuser. Maximise downforce to drag ratio. (1 student)

Chassis/cockpit (1-2 students)

1. Ergonomics and safety (inc. seat, steering system, gear shifting mechanism, fuel tank, pedal box
mounting/alterations and firewall) Access to 2016 designs at request with requirement to improve
manufacturability (with considerations towards off of the shelf components) and detail.

2. Overall assembly (all teams report to). Responsible for team leadership

3. Responsible for monitoring mass distribution to assist aerodynamics team.

Powertrain (4 students)

1. Design of differential housing, and mounts. Includes rear suspension sub-frame (needs to collaborate
with rear suspension group). Final drive ratio selection, drive shaft and sprocket design. Engine
mount design. (2 students)

2. Intake manifold finalisation and optimisation and exhaust header design and exhaust layout. Access
to 2014 intake manifold design at request. (2 student)

Other projects will be made available once the above positions have been filled, an example is:

1. Wheel centre design (1 student)