MAE 435 Progress ReportTeam: Formula SAEDue Date: 2/8/2016

Advisors: Dr. Bawab; Nathan Luetke

Presenter: Ryan P.

Gantt Chart

Aero Package• Diffuser design has been finalized • Diffuser material has been purchased to begin mold fabrication• Front nose cone mold fabrication has begun (See Attached)• Material list and layup schedule has been generated

Subgroup Lead: Jacob Crews

Suspension

Subgroup Lead: Ben Weatherford

• Completion of Design Specification Sheet for competition due date. This included a large amount of formulas and analysis of the current design.• Managed the fabrication and assembly of the uprights and control arms (See Pictured)• Suspension System Specification Binder was created for competition static event• Technical drawings for each component • Physical analysis (Via Solidworks) of each piece• Color coordinated binder and label

(Carbon Fiber Control Arm Assembly) (Design Specification Sheet)

(Front Upright Machining)

Cooling• Collaboration with the Aero team to ensure the radiator and mounting solution will fit inside the side pod •Collaboration with the electrical team to incorporate rectifier mounting on the radiator mount.• All current fabrication efforts have been focused on the cooling system. These include the following:• Swirl Pot (Pictured) Machined and welded• Radiator tanks disassembled and re welded per our

application• Thermostat Housing printed and bolt spacers machined• Individual component system Mounting

(Swirl Pot in Fabrication Stage)

Subgroup Lead: Ryan Parkinson(3d Printed Thermostat Housing)

Cost Report• All subgroups are now being imported and checked in the cost report• Overall Completion is Set at 40% and is detailed below:o Brake System - 10% Completeo Electrical System - 25% Completeo Engine and Drivetrain System - 30% Completeo Frame and Body System - 50% Completeo Miscellaneous, Fit, Finish System - 20% Completeo Steering System - 50% Completeo Suspension System - 20% Completeo Wheel and Tire System - 75% Complete

Subgroup Lead: Ryan Nagy(Spreadsheet Example)

(Ryan at it late at night)

• Disassembled rear differential in order to service differential (Change oil ect) and repair leak.

• Checked all service limits and wear patterns in the differential.• Mocked up the install of the rear differential housing• Inventoried all parts for rear axle assembly• Prepared all documentation for the manufacturing of the rear sprocket• Managed final machining of rear sprocket

Drivetrain

Subgroup Lead: Robert Higgins

(Example of design to fabrication)

• Brake System Specification Binder was created for competition static events– Technical drawings for each component – Thermo/Physical analysis (Via Solidowrks) of each piece– Color Coordinated binder and label

• Re-formatted the Brake Analysis page to enhance user friendliness as well as checking for any analysis errors. Yielded several previously undiscovered calculation errors that were then recalculated.

• Managed fabrication of all front brake components to ensure completion by deadline.

Subgroup Lead: Jon Hart

Brakes

(Waterjeted Front Caliper Mount)

(Front Rotor Carrier)

(3D printed caliper mount)

• As of this morning the car has been dropped off at local shop to have the exhaust fabricated per our design. The company is sponsoring our team and doing the fabricated at a discounted cost.

Subgroup Lead: Quan Chau

Exhaust / Parts Ordering

(Exhaust Model)

• All other efforts have been ordering parts per the departmental process and managing the FSAE budget.

Engine Oiling

Subgroup Lead: Hunter Bates

• Fabrication of oil pan complete and drain hole tapped.• Design of Oil Cooler has been completed and awaiting fabrication• All flanged has been reverse engineered and 3D printed to verify• All parts have arrived and are ready for assembly/fabrication

(Engine mounted flange Test Piece)

(Oil Pan flange Test Piece)

(Chassis mounted oil cooler)

Electrical (Last but Certainly NOT least)

• Have received all electrical parts that have been ordered up to this date• Cut and ran 85% of electrical wiring along chassis with included labels• Mocked up large electrical components and set locations• Installed terminal connectors on both brake pressure sensors, oil pressure sensor, cooling fan power and rectifier.• Completed wiring to 79-pin MoTeC connector including Ethernet cable connections• Confirmed system integration plans with driver controls and collaborated with engine cooling•Installed 50% of starter circuit• Planned with engine subgroup additional engine sensors

Subgroup Lead: Dana Griffin (Wiring “Like a Boss”)

THE END