Subprojects' Current Status

Steering

 

Current Action Items

By End of Semester

Math model of steering vs camber change (lateral force vs steering input)

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11/21/08

Solid model inserted into frame prior to design review

 

10/31/08

Solid model complete, new steering system

Determine what needs to be replaced

Update brake binder for weekly accomplishment

Work on web-site parts

 

10/24/08

Started a steering binder

Brakes

 

Current Action Items

By End of Semester

Pedal rail fabrication

Brake rotors modeled

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Thanksgiving Break

Braking force ergonomic analysis prior to design review

Pedal rail modeled prior to design review

 

10/31/08

Order new pads (racing sintered compound)

Do research for the design of the new rotors. Need to find stresses on rotors, frictional heat generation and heat dissipation of different materials.

Design new adjustable mount for pedals.

Design mounting for pedals, master cylinders, and gas pedal

Start math model including force on pedal to brake pad squeeze force, pedal travel, temperature change to rotors, etc.

Update brake binder for weekly accomplishments

Work on web-site parts

 

10/24/08

Found where we can order new pads (sintered compound)

Started research on material to use and design of new rotors

Found old pedal rail for older car (older than 07-08 car). Pedals have brake pedal, gas pedal and 2 master cylinders with reservoirs.

Started binder documentation for braking system

 

Engine

 

Current Action Items

By End of Semester

Consistent starting

Wiring diagram

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10/31/08

Put engine in car

 

10/24/08

Engine is assembled with exception of timing.

 

Drivetrain

 

Current Action Items

By End of Semester

Re-seal current differential, install, and run car. 
Modify solid model to fit slot design, bushings, 13-T sprocket, and other changes.
Check all clearances in frame.
Finalize machining drawings for all parts of powertrain.
Order aluminum for mounts.
Locate steel for custom mount tabs.
Order blank 525 13-T sprocket for machining.
Add to Drivetrain Resource Binder with updated drawings, force analysis, and spec. sheets.
Submit Design Report.

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Major Completions through 12/5/08

Modified #62 Car differential and sprocket design built and installed in current car.
Preliminary force analysis through turnbuckle and mounts.
Some seat time.
Custom drive axles designed, machined, and installed.
Custom mounts designed, machined, and installed.

 

11/14/08

Finalize Solid Model and Mastercam files for drive axles.

Pick up 4340 steel bar in Lewiston Wednesday morning from Precision Machine.

Machine drive axles Thurday.

Force/stress analysis on rear drivetrain.

Organize and finalize Drivetrain assemblies and parts.

 

10/31/08

Modify and check clearance of Drivetrain assembly in SolidWorks.

Machine bearing carriers and press bearings into carriers on Tuesday.

Machine diff. mount on Thurs.

Install diff/sprocket and drive axle on Friday-Saturday.

 

10/24/08

Machined off the steel rings on differential.
Fitted bearings on differential shafts.
Differential cleaned.
New Fafnir bearings and seals purchased and picked up today in Lewiston.
Half shaft alignment and distance checked and confirmed.
DID 525 ERV chain came in.
Correct size front sprocket found in shop and put on countershaft.

 

10/17/08

The differential was sealed with machined housing and cap. 

A leak tested was performed and no leaks arose. 

The breather tube was machined and installed in housing.

Engine parts received. 

New parts ordered because of incorrect size of piston rings.

 

 

Frame

 

Current Action Items

By End of Semester

All components tacked and finish welded

Modeled in CATIA as basis for complete vehicle model

Adjust rear main roll hoop braces to achieve 30°

Talk to AEROCET about getting free (or reduced price) shear panels.

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Thanksgiving Break

Stress analysis prior to design review

 

10/31/08

Continue FEA

 

10/24/08

Roll hoops done

 

10/10/08

Material for initial construction has been ordered.

 

 

Suspension

 

Current Action Items

By End of Semester

Begin fabrication of bell crank mounts
Fabricate all suspension mounting brackets
Finalize bell crank FEA models
Fabricate bell cranks and any other new suspension components
Continue work on solid model
Look into alternative springs/dampeners

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Major Completions through 12/5/08

New, stronger A-arms designed and fabricated
Recorded total suspension weight
New bell cranks designed
Bell crank mounts designed and analyzed with FEA, ready to fabricate
Suspension and most of car is solid modeled in SolidWorks
Front and Rear suspensions are modeled in OptimumK
Suspension binder has been compiled

Major restructuring of solid model organization

 

Thanksgiving

Solid model inserted into frame prior to design review

Identification of math models for use in fabrication & tuning prior to design review

 

10/31/08

Finalize front suspension design work
Order materials necessary for construction
Finish new front upper A-Arms

 

10/24/08

Decided on a new bell crank layout for the front suspension

Began design work on the new bell crank

Performed preliminary FEA analysis on the bell crank design
Suspension is getting back together on old car

New arms have been manufactured

 

10/17/08

Modeled force/moment inputs for worst-case scenario loading on chassis

Began collection of suspension resources in a binder

Began building new end rods for the failed suspension linkages

 

Cooling

 

Current Action Items

End of Semester

New components on order

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Thanksgiving

Selected radiator size and configuration prior to design review

Proof of concept via thermal systems model prior to design review

 

10/31/08

Prep for testing.

 

10/24/08

On hold till engine testing