Formula SAE Research Articles

Design of a Yokeless double disc axial flux motor for light electric vehicles

One of the main challenges in designing electric vehicles is determining traction system performance, as engine power directly impacts battery size and the engine itself. Therefore, high power density, efficiency, and torque are all essential for vehicle autonomy and performance. This study proposes developing a dual-disc axial synchronous motor for Society of Automotive Engineers (SAE) Formula-type light vehicles. It addresses key motor design parameters such as current, terminal voltage, winding configuration, and reactances. The objective was to meet demands for specific vehicle dynamics, e.g., a wide RPM range, high torque, and dynamic performance. These parameters were validated using finite element simulations, which were then compared to a three-phase induction motor in a simulation software used by the Cheetah vehicle racing E-competition team. The motor designed here aims to provide superior dynamism, especially given the absence of reduction systems, which in turn reduces the losses associated with transmission ratios. This study not only details the dual-disc AFPM engine design process, but also validates it using finite element simulations, and presents justifications for improved dynamic performance and efficiency relative to an engine used in a Formula SAE competition. The side-by-side comparison clearly showed significant gains in speed, and significant reductions in lap time for the motor developed here.

Numerical Optimization for Aerodynamic Performance of Nose Cone of FSAE Vehicle through CFD

This paper presents the optimization and aerodynamic performance of a Formula SAE vehicle nose cone. The purpose of the study is to minimize drag while simultaneously enhancing downforce to improve traction and acceleration of the vehicle. Numerous CAD models of the nose cone were developed, taking into account factors such as chassis dimensions, ground clearance, and Formula SAE rulebook constraints. Computational Fluid Dynamics (CFD) analysis is carried out in ANSYS 2021 Fluent module. The fluid domain was created and meshed using tetrahedral cells, and the flow field was predicted using the Realizable k-ε turbulence model. The simulation results revealed essential information including drag and lift coefficients, as well as pressure and velocity contours. An in-depth analysis of lift and drag coefficients guided the optimization of the nose cone design. The study ultimately identified a nose cone design that yielded the most favorable drag coefficient and is found in the range between 0.2-0.3. The study also observed that the down force is increased by 27%. This design proved highly effective in reducing the vehicle's drag and sufficient downforce to enhance acceleration.

DFA Analysis Revolutionizes FSAE Steering, Enhancing Efficiency in Automotive Design

In the dynamic realm of automotive engineering, particularly in Formula Society of Automotive Engineers (FSAE) racing, where vehicle assessment is based on efficiency, motor power, chassis dynamics, and steering, there exists a notable focus on steering system design. This research delves into the conceptualization and component development aimed at aiding automotive mechanics in crafting steering systems for FSAE race cars. Employing Solid Edge 2021 software, the study utilizes the Design of Assembly (DFA) analysis method to streamline the mechanical process. Through DFA analysis, the study assesses various Technical Attributes (TAs) of the steering system, revealing values ranging from 0.548 to 1.765. The ideal steering system ensures that the desired steering input by the driver aligns with the output motion of the vehicle, known as the Ackerman condition. Steering gear mechanisms translate rotational motion into translation and adjust the effort applied to the steering linkage. The study's findings contribute to the advancement of steering system design in FSAE vehicles, emphasizing ergonomic considerations and the utilization of advanced software tools like Catia and Solid Edge 2021 for enhanced performance and safety. Highlight: FSAE steering: DFA analysis enhances design efficiency for racing vehicles. Software aid: Solid Edge 2021 streamlines FSAE steering system development. Ergonomic focus: Design prioritizes driver comfort and vehicle performance optimization. Keywoard: FSAE vehicles, Steering system design, DFA analysis, Solid Edge 2021, Ergonomics

Dynamic Cornering Fatigue Test of New Lightweight Racing Wheel for Formula Society of Automotive Engineers (FSAE) Race Car

Dynamic Cornering Fatigue Test of New Lightweight Racing Wheel for Formula Society of Automotive Engineers (FSAE) Race Car

Static analysis of new lightweight racing wheel for Formula Society of Automotive Engineers (FSAE) race car for product innovation

A lightwheel has the potential to be widely used to enhance the safety of racing cars and improve car performance by providing an estimation of wheel width spokes quantity, and other constant variables. This study is, therefore, aimed at designing a new lightweight racing wheel. In this study, a Finite Element Model (FEA) was implemented to investigate the static analysis of the newly designed lightweight racing wheel. Since the lightweight wheel characteristics play an important role in the stability and control of the racing car under severe manoeuvres, the wheel mass, von Mises stress, deformation, and safety factor were determined. It was observed that the circumferential component is vital for estimating the lightweight design of racing car wheel design. Therefore, this parameter could be better assessed for future studies.

Enhancing oil pressure dynamics in a high-performance racing engine with innovative lubrication system tuning

This work focuses on fine-tuning the oil pressure dynamics of a single-seater formula car, a participant in international engineering competition organized by the Society of Automotive Engineers (SAE). Adhering to competition guidelines, the Honda CBR600RR 05-06® motorcycle engine, renowned for its 600 c.c. displacement and exceptional power-to-weight ratio, emerges as a popular choice. However, as this engine is originally equipped with a wet sump lubrication system (featuring deep wet sumps to prevent oil starvation during turns), this presents challenges when adapted to Formula Society of Automotive Engineers (FSAE) cars. Cornering leads to significant pressure drops, as sloshing exposes the pickup port, causing consequential engine issues. To tackle sloshing-related challenges and pressure loss during lateral and longitudinal g-forces, a dry sump lubrication system was introduced in the Formula car. The dry sump system also lowers the engine’s center of gravity, by reducing sump height. However, transitioning to the dry sump system and integrating it with the existing engine demanded extensive design modifications to various components, including the oil reservoir, lubrication lines, scavenging pump, and oil ports. These adjustments were essential to achieve the targeted elevation in oil pressures at higher engine RPMs. A relationship between the engine oil pressure and the engine RPM was developed as part of the study.

Suspension and tyre loads estimation of an FSAE car: model development and on-track validation

In this paper a relatively simple model is presented, able to compute the loads on the suspension arms and at the tyres' contact patches of a Formula SAE car starting from telemetry data. The model is based on standard dynamic equilibrium equations, a simplified assumption for the limited-slip differential and a given front-to-rear brake distribution. The model inputs are the signals acquired with common telemetry sensors, which usually equip a Formula SAE vehicle (Inertia Measurement Unit, GPS, potentiometers, Hall sensors). In order to validate the model, some arms of the suspensions were instrumented with strain gauges, and a kinematic model of the suspension, together with its static equilibrium equation set, was set up to relate the arm loads to the forces acting at the tyre-road contact patch. The suspension kinematic and equilibrium models were first validated through static tests, with known forces applied at the wheel hub. Then, the complete vehicle model was validated by comparing the same quantities, relative to some real driving tests on a kart circuit, showing a fairly good agreement between the predicted and the measured loads. The model represents a valuable tool for vehicle design and development for the Formula SAE team.

Design and Development of a Brake Test Bench for Formula SAE Race Cars

The optimization of the brake systems is crucial for vehicle performance and safety of Formula SAE (FSAE) race cars. This study introduces a specialized brake test bench designed to enhance the understanding and testing of these systems. The bench integrates a rotating mechanical system mounting a brake disc-caliper group, which is driven by an electric motor, a pneumatic brake pedal assembly to simulate real braking conditions, and a comprehensive array of sensors that facilitate the measurement of critical parameters, such as rotation speed, braking torque, oil pressure, and disc temperature. Its structure, sensor integration, and control electronics are fully described, demonstrating the capability to replicate on-track scenarios in a controlled environment. The results underscore the utility of the bench in providing precise and consistent testing conditions essential for analyzing the efficiency, durability, and safety of the braking systems of FSAE race cars.

Finite element analysis and optimization of a Formula SAE car chassis

In motorsport engineering, achieving the ideal balance between speed, agility, and safety is a monumental challenge. Formula SAE competitions, where collegiate racing teams design high-performance vehicles, emphasize the pivotal role of the chassis, the backbone of the racing machine. Ensuring chassis compliance with regulations and optimizing structural integrity and weight is a formidable task. This study addresses this multifaceted challenge by focusing on the development, simulation, and optimization of a Formula SAE car's chassis. Rigorous analysis of four chassis versions seeks to strike a balance between rigidity and weight, enhancing performance while adhering to rules. Longitudinal torsion, diamond torsion, lateral acceleration, and braking tests assess structural rigidity and stress distribution, ensuring predictability and preventing potential failures. The mesh uses one-dimensional elements (1 mm size) and material properties akin to SAE 1020 steel. The fourth iteration consistently demonstrated superior performance across all tests. Despite a slight weight increase, it exhibited a longitudinal torsional rigidity of 1985 Nm/deg, well-aligned with Formula SAE standards, and a formidable diamond torsional rigidity of 56,304 Nm/deg. Critical stress analysis during lateral acceleration and braking tests remained well within permissible limits, with a chassis weight of approximately 35 kg. In summary, this work meets stringent Formula SAE standards, offering a systematic methodology for chassis design and optimization. The fourth iteration excels in various critical tests and serves as a valuable contribution to motorsport engineering, providing a blueprint for enhanced competitiveness and performance in the 2023 Formula SAE Brazil competition.

Analysis and improvements of a front wing for formula SAE car

Although aerodynamic packages have been developed for many years, teams still face the problem of lack of downforce and how to control the turbulence. One possible reason is that the size of a formula SAE(Society of Automotive Engineers) car is strictly limited. It is unrealistic to blindly copy Formula 1's aerodynamic package without improving. Aided by CFD (computational fluid dynamics), this article focuses on the front wings aerodynamic characteristics in order to modify the downforce and the flow field around it. The front wing is divided into two parts, one is to direct the airflow bypass the tires, and the other is to diminish the airflow lifted by the front wing. Moreover, a special flap is designed to control the airflow and achieve good results. This article also shows the airflow around the whole car with aerodynamic packages to make the results more vivid. This article may offer a reference for the front wing design of race cars.

Retracted: The Development of Data Acquisition System of Formula SAE Race Car Based on CAN Bus Communication Interface and Closed-Loop Design of Racing Car

Retracted: The Development of Data Acquisition System of Formula SAE Race Car Based on CAN Bus Communication Interface and Closed-Loop Design of Racing Car

Systems engineering in automotive product development: A guide to initiate organisational transformation

Systems Engineering (SE) is an engineering method that has rarely been applied in Automotive Product Development, despite its noticeable positive effects in other engineering fields. With increasing interests, firms and scholars have started to discover its impact in the segment, however internal hurdles appear when it comes to implementation practices at organisations across the industry. This paper presents a comprehensive guideline, results and good practices on the SE implementation, developed in Formula SAE (FSAE), which is a relevant model environment of automotive industry. The impact of applying SE show project results improvement in cost, time and quality aspects, although, the maturity of SE should be assessed at the system of systems level. Outcomes gained from FSAE have been validated by in-depth interviews with SE experts, engineers and managers affiliated at technical development departments of 4 different automotive OEMs. These practitioners provide evaluated practices as employee involvement, applying learning by doing, and playing with architectures relevant and feasible in industrial setting, however emphasized expected impeding factors as sluggishness and general resistance to organisational changes.

Lightweight Design and Analysis of Steering Knuckle of Formula Student Car Using Topology Optimization Method

The steering knuckle is a crucial component of student racing vehicles, designed by the Formula Society of Automotive Engineers (FSAE). Developing a lightweight (LW) vehicle that meets the requirements of the student formula car presents a challenge. This study presents a LW design of the steering knuckle using the Topology Optimization (TO) approach for the Formula Society of Automotive Engineers (FSAE) competition considering two different mass constraints (40% and 48%). Moreover, the research includes Stress–Life (SN) curves for three materials, structural steel, 4130 steel, and AISI 1020 steel, providing essential insights into the fatigue characteristics of the model. The results compare the three materials and two mass reduction levels, with steel 4130 achieving a significant mass reduction of 42.70%. Additionally, steel 4130 exhibits superior performance in weight reduction, stress, deformation, and safety aspects. The optimized design meets the criteria for strength, stiffness, and safety under various conditions. The fatigue analysis reveals that AISI 1020 and steel 4130 have superior endurance (1 × 105 and 2 × 105 cycles, respectively). This research provides significant contributions to the development of a LW, high-performance steering knuckle for student formula racing vehicles, highlighting the significance of TO and material selection in achieving optimal outcomes.

Performance Prediction of a 4WD High-Performance Electric Vehicle Using a Model-Based Torque-Vectoring Approach

Electric vehicles (EVs) enable the integration of powertrains with multiple motors, allowing for the adjustment of torque delivered to each wheel. This approach permits the implementation of torque vectoring techniques (TV) to enhance the vehicle’s stability and cornering response, providing better control of yaw moments. This study utilizes comprehensive telemetry data and an advanced simulator model to assess the influence of torque vectoring (TV) on a Formula SAE (Society of Automotive Engineers) competition vehicle. The telemetry data were collected from a fully instrumented 2WD car, which was then employed to calibrate the simulation model. The calibrated model was subsequently utilized to predict the performance enhancements that could be achieved by implementing a 4WD system. The methodology proved to be a valuable contribution to vehicle design development. This approach also helps evaluate the potential advantages of torque vectoring for drivers with limited experience.

Numerical and experimental analysis of the bodywork of a Formula SAE 2023 type vehicle

In the present study, the aerodynamic characteristics of a bodywork for the Formula SAE 2023 competition were analyzed. Based on the requirements of the international competition regulations and the ISO 10521 standard, a numerical evaluation procedure was defined based on a CFD (Computational Fluid Dynamics) analysis. A bodywork model is presented and essential aerodynamic parameters were taken into account for the definition of the flow analysis models, where the k-omega model was used in the turbulent flow analysis. Additionally, an experimental analysis assembly was prepared through a wind tunnel at the University facilities, using a model of the bodywork by 3D printing at a scale of 1:43 with thermoplastic polyurethane material. Results of pressures, flow lines around the different elements of the bodywork were found, as well as drag coefficient values from 0.42 to 0.55, the latter were compared with others obtained by other Formula SAE teams, they found similarities in the results obtained. Additionally, with the wind tunnel, the comparison of the current lines was obtained, which showed similarities in the experiment and is expected to be improved in future studies.

Exact shell solutions for conical springs. III. Belleville springs with variable thickness

PurposeIn the current manuscript, the authors examine the Belleville spring with the variable thickness. The thickness is assumed to be variable along the meridional and parallel coordinates of conical coordinate system. The calculation of the Belleville springs includes the cases of the free gliding edges and the edges on cylindric curbs, which constrain the radial movement. The equations developed here are based on common assumptions and are simple enough to be applied to the industrial calculations.Design/methodology/approachIn the current manuscript, the authors examine the Belleville spring with the variable thickness. The calculation of the Belleville springs investigates the free gliding edges and the edges on cylindric curbs with the constrained radial movement. The equations developed here are based on common assumptions and are simple enough to be applied to the industrial calculations.FindingsThe developed equations demonstrate that the shift of the inversion point to the inside edge does not influence the bending of the cone. On the contrary, the character of the extensional deformation (circumferential strain) of the middle surface alternates significantly. The extension of the middle surface of free gliding spring occurs outside the inversion. The middle surface of the free gliding spring squeezes inside the inversion point. Contrarily, the complete middle surface of the disk spring on the cylindric curb extends. This behavior influences considerably the function of the spring.Research limitations/implicationsA slotted disk spring consists of two segments: a disk segment and a number of lever arm segments. Currently, the calculation of slotted disk spring is based on the SAE formula (SAE, 1996). This formula is limited to a straight slotted disk spring with freely gliding inner and outer edges.Practical implicationsThe equations developed here are based on common assumptions and are simple enough to be applied to the industrial calculations. The developed method is applicable for disk springs with radially constrained edges. The vertical displacements of a disk spring result from an axial load uniformly distributed on inner and outer edges. The method could be directly applied for calculation of slotted disk springs.Originality/valueThe nonlinear governing equations for the of Belleville spring centres were derived. The equations describe the deformation and stresses of thin and moderately thick washers. The variation method is applicable for the disc springs with free gliding and rigidly constrained edges. The developed method is applicable for Belleville spring with radially constrained edges. The vertical displacements of a disc spring result from an axial load uniformly distributed on inner and outer edges.

Utilising Magnus Effect to Increase Downforce in Motorsport

The Magnus effect is the generation of a sidewise force on a spinning cylindrical or spherical solid immersed in a fluid (liquid or gas) when there is relative motion between the spinning body and the fluid. This is most commonly seen in baseball, tennis, or European football where the ball’s trajectory is curved due to its rotation. The idea of using the Magnus effect in an airfoil to produce lift was proposed in 1941 in a patent application by Massey. This is also known as Kutta–Joukowski lift, first analyzed by Kutta and Joulowski in the late 19th century. In maritime applications, it is known as Flettner rotor sails, first used in the 1920's. Although Magnus effect is not new, the idea of using it on a racecar wing to improve downforce has not been extensively studied. The concept is to replace the front leading-edge of the wing with a rotating cylinder of the same diameter to produce additional circulation around the foil. This idea was born out of discussion at San Jose State University’s Formula SAE team as a way to create variable downforce on their wings. Although the idea was proposed but it was never built because of the complexity in the construction and a lack of rigorous analysis. Subsequently from our CFD simulation, it shows that by imposing a +2U angular velocity to the front LE cap (i.e., rotating upwards in the negative-x direction), we could gain 4.25% of downforce. Since the leading edge cap is roughly cylindrical, physically replacing it by a cylinder would not cause a visible change to the race car’s geometry while improving the aerodynamics using Magnus effect. This CFD data show promise to take the next step of building a physical prototype and perform aerodynamic experiments to validate this finding. Keywords: Magnus effect, aerodynamics, downforce, CFD, motorsport.

Effects of Radiator Angle and Sidepod Profile on Aerodynamic Performance of a Race Car

In Formula Society of Automotive Engineers (FSAE) cars engine heat management serves as an important factor for the performance of the vehicle. Therefore, a proper design of sidepod is crucial for optimal cooling of the engine since sidepods are designed to direct the airflow through the radiator. Also, since sidepods play an important role in the aerodynamic performance of the vehicle, factors such as drag and lift must also be considered along with the cooling of the engine. This paper brings forth the methodology carried out to design the sidepods effectively. First the optimal radiator angle is determined on which the maximum mass flow rate of air through the radiator core is observed. Angles are varied from 50, 70 and 90 degrees on various orientations with respect to the car. Fixing this radiator angle, various inlet and outlet areas of the sidepod are analyzed. Choosing the model with least drag and lift coefficient the sidepod is analyzed by sealing it at various sides. Finally, the effects of gills are also analyzed for better optimization of the sidepod. The models are designed in Solidworks and the CFD simulations are carried out in Simscale. Half car simulation is performed with symmetry conditions in order to reduce the cell count. The results of the analysis showed that the radiator angled forward with a diverging type sidepod yields in the better cooling of the engine.

Understanding and acceptance of systems engineering in automotive product development

Systems Engineering (SE) is a new engineering method for many firms in Automotive Product Development that expectedly advances their development processes to meet their stakeholder needs more effectively. Literature suggest that understanding and acceptance are key factors in the implementation, however comprehensive modes for their increase are barely discussed. In this paper, we propose a Participatory Action Research based on multiple research elements to find an effective technique for gaining understanding and acceptance on SE in a validated model environment of automotive industry called Formula SAE. We present practical outcomes at each steps of the implementation process and analyze the effect of improvements in the context of strategy, structure processes.

Thermal and Static Properties Investigation of Different Intake Manifold Materials to Lower Air Intake Temperature for Improved Engine Performance

Formula SAE competition is targeted at students who are interested in designing and developing a Formula-type race car. Rules were imposed to restrict the car’s performance for safety besides encouraging problem-solving skills. One such rule is the requirement of a 20mm restrictor inserted between the carburettor and intake manifold to reduce the air intake. With a constricted airflow creating a bottleneck effect, less air will be provided to the engine for combustion, consequently reducing engine efficiency. The purpose of this project is to overcome this problem despite the restriction imposed by the rules. This is done by choosing an intake manifold material that provides a low air temperature while withstanding the stress and vibrations from the engine. Computational Fluid Dynamics (CFD) software was used to conduct the static, thermal and modal analysis of Aluminium Alloy 6063, Gray Cast Iron, Fibreglass Epoxy and Carbon Fibre Epoxy to choose the material that produces lower intake air temperature while maintaining high strength. Carbon fibre epoxy was found to provide the best durability against static stress while maintaining a lower intake air temperature compared to the other materials tested.