Update

Hey guys! So to be honest, I really have no idea how many people are reading this at this point, or if there is any one at all. But I am ok with that and am sure that within due time...

So how about an update? Sure.
I am back up at school and am quite busy, but it seems that almost every weekend I put in a few hours or so. I like to think of work and projects like an engine, the harder you work (the higher quality of fuel you put into the engine), the more 'work' (haha get it? Yeah I am an engineer, so what?) you get out. And getting tools, like a new computer, a better CAD or CDF package, or new calculator, is like building a better engine, adding nitrous, or boost or something.
ANYWAY, yes I am quite busy but am getting somewhere. I have been doing a lot of work on the rear setup and drive train equipment. This picture here is the rear assembly that I have been working on. Its still in progress, but the basic idea and most of the details are there. The idea is to mount the suspension, single rear brake, and most of the drive train all in one housing. The box is made from 5 major pieces with some bracing here and there. Recently I have done some FEA on the box to see what kind of numbers I can work with. Luckily most of the results have been positive, with the lowest factor of safety around 15. I have not done all the tests I want to, and those were all rather quick (20 min max). I want to bump it up and actually simulate some of the hardware and fasteners needed to hold the thing together and see if I get similar numbers.

Since I don't have much in terms of suspension geometry, this could all be for nothing in the end if I am not pleased with the product. I tried to make this as flexible as possible for when that day comes, but there is always a chance I missed something. We shall see.

Well I wanted to make an update, but keep it short, so I think I will end it here. Have a good one.

One Step Backwards, Two Forward

Welcome to the new year. I am excited for 2010, for this is the year I graduate and I'm sure a lot of other good things will come.

I feel like I need to take a step backwards before I continue. It seems like I maybe getting ahead of my self. For those of you who know what F1000 or FSAE is all about, you can probably pick up on this stuff quickly. For those of you who are not all that familiar with them, this post should really help you out.

I figured I would go through and talk about the "Big Picture". The overview of the car, what I want to get done, that kind of stuff. So lets get crackin'.

Over all car
I want to build a car that meets F1000 racing rules and is allowed to complete. The car needs to be within all specifications and meet all restrictions. Also, the minimum weight for the car is 1000 lbs, I would like to be within 100 lbs of that. What else can I say here... oh yes the color, Bullitt Green.

Frame or Chassis
Since this is my strong point I can say a bit about this frame. I want a frame that is as light as possible and as strong as possible. It needs to fit me and the motor I am thinking about using. Also I want to use a type of modular suspension mounting system that is commonly referred to as a 'chocolate block'. If you check out this picture, notice the little block sticking out where the suspension mounts are. Those are often called 'chocolate blocks' and I used a similar idea for my chassis. If you were to look at one of the older posts and notice the square tubing in the fore section of the car, that is where these blocks will be mounted to. For some actual numbers, I would like the frame (with motor) to be about 2500 - 4000 lbs/degree for the torsional stiffness and a weight under 200 lbs. I do think I can get the weight under 100 lbs and the stiffness above 3500 lbs/degree, but a little room to breathe is always good.

Suspension
Now I know that suspension is one of the most complex parts of a race car right next to engine design, and I have no problem saying that I am still learning a lot about it. I can say that I will be using a double A-arm type suspension with 4 push rods and an anti roll bar. I need to start looking at some mountain bike springs and shocks and determine what is good for my application. Other than that, I know that I would like to tuck away the uprights in the tire and use streamlined tubing for as many of the members as possible. The rest I will have to learn as I go and see where the road takes me.

Engine
As for the power plant, a CBR1000rr is on my scope. At Clarkson we use a CBR600F4i and have had a lot of luck with it so I would like to use a similar motor. Now the rules say that the stock electronics and ECU need to be used, but it also says a piggy back fuel mapping system is allowed. I will definitely look into that. Just about everything else needs to remain stock, and so it shall.

Drive train
As for getting the power to the wheels, I would like to use a Torsen differential. Once again at Clarkson we have used one for many years and it has truly left a positive impression. I have done some MatLab work to determine my gearing ratio and some other things like distance from engine to differential ect. I also want an inbound break on the differential to help reduce my unsprung weight in the rear. It will be larger and I will have to do some duct work to help cool it off, but it seems worth the effort. Also I would like to construct a rear box from aluminum that not only holds the suspension, but the diff, shocks/springs, and rear brake.

Aerodynamics
Wings. The F1000 rules say that wings are needed, and even if they didn't, I would still like to use them. Also a under body diffuser is great too, you can reduce drag and increase down force, seems like a win-win here. I am also looking at a front and rear wing for increased down force. For the rear wing, I am going to look at mounting on either side of the wing, or a pedestal mount. After viewing some videos of F1000 cars in race, I see the wings vibrating furiously and being an aeronautical engineer I know that the vibrating is not helping with drag or down force. So I will construct a small trade study to test which will yield the best results.

And that's about all the basics for now. I hope that helps put a little more direction to this blog. And as always, more to come.