SAE Formula Essay Examples

I attended SAE Formula sessions which usually takes place on Wednesdays 4 pm where I learned quite a number of practical lessons.
The first session took place on Week 3, 28 Jan 2015. We learned about the chassis. The design problem faced were that the main roll hoop was not rule compliant while the new one ordered was expected to arrive Jan-29th. Meanwhile we decided to tack the new role hoop onto the chassis and begin assembling the suspension components for rolling chassis. On the suspension part we realized that the silver horse was not matching with the piece of the spars. So we decided that it was going to be remade while we continue working with other spar components. On the other hand, we encountered a challenge in the power train. There was a mis-calibration of the Motec software. The team decided to call Motec to provide technical support and fix the software. We also decided to complete assembly of the components of the upper power train. On the aerodynamics, we discovered that there was a challenge obtaining carbon fiber composite. Everyone was also new to the composite layup. As a result, we decided to seek sponsorship for additional foam and carbon fiber. Furthermore, we fully refined the carbon fiber seat.
4th Week, 4 February 2015 was the second session. In this day, we had two challenges about fixing the chassis. The first was about head rest attachment position which needed to be modified due to new rules and the gap between the holes and the head rest plate. We then decided to drill holes on the chassis for the seat attachment, attachment to the frame, tabs for suspension, and also for the aerodynamic components. On the suspension, the rear pushrod attachment tabs need adjustment to match final suspension points. We then went ahead to complete rolling chassis remaining components which included machining the remaining spar components, cutting and preparing rear carbon tubes, gluing inserts, and welding steel a-arms and glue to carbon tubes. On the powertrain, we had a challenge about engine idling at high RPM. There was also a deviation in the 3D print of FP 15 intake. The team decided that we continue tuning the engine, and go ahead to sand and seal FP15 intake with PlastiDip. We also had to seal the FP14 intake for better tuning. Other tasks included adjusting differential for left hand driven settings and contact Titan Motorsports for dyno-tuning sponsorship. In the aerodynamics and the body parts, there was a delay in the arrival of the foamed parts so we began to layup for side pods and nose cone. Later, we manufactured the winglets and adjustment mechanism.
5th Week 11 Feb 2015. The chassis problem was about suspension tabs that were not trimmed accurately, team manually faced each tab to fit tubes properly. The team agreed that we mount the seat attachments to the frame, bolt head rest plate to the head rest tabs, and fit spars and engine to the frame. There was also a challenge on the suspension. For example, the rear rocker had some minor issues and needed to be revised, most parts needed to be manufactured using the CNC machine and thus slowing progress, and the shapes sponsorship was no longer viable. Following this, the team decided to manufacture and weld together all necessary parts. However, when we went to the powertrain, the coolant overflow was not connected properly. We proceeded to wet sand FP-15 runners to perfection, improve tuning of car, mount spars to the FP-15 chassis, machine sprocket mount, and create and weld tabs for powertrain components. But on the aerodynamic parts, there were two main challenges. The first one was that the foam for body panels has not arrived. The second one was that the CNC machine botched the nose cone mold due to an unexpected tool change, fixed using Bondo. Following this, the team decided that we begin to process and sand created molds, finish the molds for the body panels, and also begin to layup carbon fiber of the remaining parts.
6th week. 18th February 2015. There was a delay in tacking and welding components on the chassis. We continued tacking chassis and other sub team’s components to the frame and finally we attached the head rest foam to the head rest plate. On the suspension the problems were that most parts need to be manufactured using the CNC machine, slowing progress. There was also the problem that the uprights did not pass analysis in ANSYS, thus requiring extensive redesign and analysis in progress. We then went ahead to weld arm pieces together and also glued aluminum and steel inserts followed by finalizing of the upright design and analysis. Lastly, we manufactured some parts including spar a-arm connectors, Argyle/YA brace, uprights, and upright bracket. In the powertrain the main challenges were choosing the correct load point to tune fuel map and ignition advance map, the exhaust require to be revised numerous times to ensure criteria and requirements are met, and there was also limited access to afterhours project room access. Still, the team concluded that we should seal FP15 intake and mount it to the engine, continue tuning, mount fuel components, and apply oil to differential discs, on firm exhaust calculations with Dr. Micklow, and end out exhaust to be manufactured by SPD Exhausts. We also encountered some challenges on the aerodynamic body which included that the CNC time at the machine shop has been limited due to other parts made, the body panels had to be split into thirteen pieces as opposed to the original nine. All these were a result of limitations in CNC. We proceeded to begin smoothing of currently made molds and confirmed side pod layup method.
7th week. 25th February 2015. There was the problems associated with the chassis again including delay in tacking and welding components due to broken welder and tabs that needed to be remade due to manufacturing issues. But we continued to tack the chassis and other sub team’s components to the frame, followed by fitting the spars and the engine onto the chassis. Suspension too, had some challenges. First, there was a need to redesign uprights slowed the sub team on other components. The welder also broke and delayed the welding of the steel a-arm tabs. As a result, we proceeded to manufacture the necessary parts, glued the aluminum sections together, and steel insert tubes. In the powertrain, we found out that there was fouling of the spark plugs delayed the SAE Event and that the engine shuts off at around 5,000RPM when dropping from a higher RPM value. After noting these, we went ahead to improve tuning of car, quote request from SPD Exhausts, order drivetrain components from RCV, begin manufacturing shifter mounting plate and start setup, and revise the hand clutch manufacturing process. On the aerodynamic section, the major problem was still that the foam filler takes time to cure before it can be sanded. We went ahead to complete the gluing of the body panel molds, thoroughly sand and smooth the sections, began fiberglass layup for female mold, and also began carbon fiber layup.
8th week. 4th march 2015. Three problems we encountered on the chassis included asymmetric geometry of frame affected placement of spars and engine, delay on re-manufacturing suspension tabs, and that head rest position change due to the adjusting of the frame. The team decided to re-manufacture suspension tabs and use a-arms to ensure optimum fit, mount seat, mount steering rack, and tack anti-intrusion plate. However, on suspension, the problems were that the welder was broken until yesterday and the welding of the a-arm tabs was delayed and the Nilos rings out of stock at SKF. We had to manufacture the parts we required and glued other parts to the chassis. Powertrain challenges included the challenge of controlling the amount of fuel being unnecessarily being pumped and the engine bolts were too short for mounts. We then improved tuning of the car, and also measured and order drivetrain components from RCV. Finally, we mount smaller components. The aerodynamic parts had major problems including filling and smoothing all gaps was slightly difficult and that pieces on the left side body panel had to be put back in the CNC. We continued to finish filling gaps with sanding compound, get the sanding compound sprayed on, and completed the process both left and right side body panel molds.
11th week. 25th march 2015. We continued with our advisement with the challenges and coming up with solutions. This time, there was a problem with the suspension tabs re-fitted with suspension assembly and anti-intrusion plate remade due to incorrect hole size in the chassis. We decided the best approach was to drill holes on impact attenuator to attach to the chassis, tack anti-intrusion plate, glue headrest foam to headrest plate, and manufacture aero tabs for body attachment. On suspension part the problems were that the front uprights were machined a quarter inch thicker than indicated in drawing and the brackets were also thicker and had to be adjusted. We had to CNC two remaining argyle brace pieces and complete steering components. On the powertrain, the challenge was about the oil sump plug protrudes below chassis causing rules violation, the brake tools which flare the lines broke, and the wire harness may hinder some of the other sub teams before packaging. To solve this problem, we cut and mount driveshaft's, mount intake after welding exhaust, fill fluids and leak test, and start engine. Finally, on the aerodynamic section the problem was that the ordered more sanding compound to release parts from other molds, carbon fiber side pod pieces lacking desired rigidity, fiberglass side pods are being considered, and rejected carbon fiber side pod saved to justify the possible change. Then to address these, we finished the carbon pieces for the left side body, right side body, and nose cone, and mounted the body and side pods, and installed the winglets.
During the presentation, the team performed very well. It was an impressive and detailed presentation. In my evaluation, I can award them a B. The presentation was very clear and easy to understand. Even someone with little background in engineering can get the idea. Overall, I learned a lot from the advisement sessions and I believe I would be a better student next year. I would have no difficulty taking more complex assignment on the subject since I believe this is the strongest foundation in my course. The advisements has also equipped me with good presentation skills, problem-solving skills, teamwork, and communication skills which I believe are very important in my future endeavors.