Free-Wheeling

The objective was to build open-wheeled race cars for the Formula SAE student competition. Cars are evaluated on performance, design, and cost metrics. It is a design-build challenge with tight timelines and student-led outside the normal curriculum. Over the years my contributions evolved from a junior, to a leadership, to a mentor role.

My contributions focused on the drivetrain (although I lent a hand everywhere else). This encompassed everything following the output sprocket of a 600cc motorcycle engine: chain drive; limited-slip differential; drive shafts; CV joints; wheel hubs; and supports. Early designs featured Volkswagon components which were modified for weight reduction. For the 2010 car, I had the mandate to redesign the whole system. The result was lighter, smaller, stiffer, and less leaky than previous generations. The design was continued for 2011.

I developed design and fabrication skills across a spectrum of manufacturing technologies, e.g.: CAD/CAM/FEA/CFD; CNC machinery; metal fabrication; manual machining; composites work; etc. There was also design and contracting for specialty processes such a gear cutting and heat-treatment.

Overall outcomes comprise: fabricating the 2007(#16) car; designing and fabricating the 2008(#27) and 2010(#16) cars; and mentoring (with some fabrication) the 2011(#32) car.