concurrent engineering
DESCRIPTION
A manufacturing process study for a formula style racecar chassis. Project\'s objective was to reduce manufacturing costs by simplifying certain parts of the frame while maintaining satisfactory rigidity.TRANSCRIPT
![Page 1: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/1.jpg)
Final Design
Jed EscovillaJoe FiniBen LyJesse ThompsonGustavo Ortiz
ME 138: Formula SAE Chassis
![Page 2: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/2.jpg)
Goals and Ideas 2010 Chassis
Torsional Rigidity:
370 lb-ft / degree
The Use of FEA
![Page 3: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/3.jpg)
F-SAE 2010 Chassis: Weight
Weight:
Under 63 lbs
The Lighter
The Faster
![Page 4: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/4.jpg)
F-SAE 2010 Chassis: Comfort
Drivers Seating Angle & Front Hoop:
Increase Comfort and Ease Driver Egress
![Page 5: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/5.jpg)
Concurrent Engineering Principles Used
Design for Manufacturing Design for Cost Design for Serviceability
![Page 6: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/6.jpg)
Design for Manufacturing
Redesigned frame has reduced amount of welded joints
Reduced the number of tubing for the frame
![Page 7: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/7.jpg)
Redesign of Front Hoop
2009 front hoop had too many butt welded joints, these are replaced with bends.
![Page 8: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/8.jpg)
Reduction in Frame Tubing
Removed tubing from engine mounting structure
![Page 9: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/9.jpg)
Design for Costs
Manufacturing Costs were reduced by :Replace welds with bending when possibleReducing number of tubes for frame
Material CostsSteel used for frame increased but only by a
small amount to make up for loss rigidity.
![Page 10: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/10.jpg)
Design for Serviceability
Main hoop bracing redesign for engine serviceability.
![Page 11: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/11.jpg)
FEA ANALYSIS AND TESTING
![Page 12: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/12.jpg)
Torsional Rigidity
Without proper rigidity significant frame bending occurs (strain)
With major flexing in the frame, clearances will be affected
Frame flex induces forces not originally intended
![Page 13: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/13.jpg)
Torsional Rigidity testing
Ft-lbs
degreeUnits:
![Page 14: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/14.jpg)
2010 Frame Rigidity
![Page 15: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/15.jpg)
Race Conditions Simulation
Applying loads during race conditions Most extreme case: Turning
![Page 16: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/16.jpg)
FSAE Autocross Conditions
D7.2 Autocross Course Specifications & Speeds
D7.2.1 The following standard specifications will suggest the maximum speeds that will be encountered onthe course. Average speeds should be 40 km/hr (25 mph) to 48 km/hr (30 mph).
Straights: No longer than 60 m (200 feet) with hairpins at both ends (or) no longer than 45 m
(150 feet) with wide turns on the ends. Constant Turns: 23 m (75 feet) to 45 m (148 feet) diameter. Hairpin Turns: Minimum of 9 m (29.5 feet) outside diameter (of the turn). Slaloms: Cones in a straight line with 7.62 m (25 feet) to 12.19 m (40 feet)
spacing. Miscellaneous: Chicanes, multiple turns, decreasing radius turns, etc. The
minimum track width will be 3.5 m (11.5 feet).
F=20.5slugs*44ft/s^2/29.5ft = 1,331 Pounds of Force
OR (66ft/s^2)/(32.2ft/s^2)=2 *Gs
![Page 17: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/17.jpg)
COST
![Page 18: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/18.jpg)
Cost Event – The Cost Event Rules (abbreviated)
1. Standardized Prices – The prices for parts, materials and processes have been standardized and the prices in the official Cost Tables must be used. If you use a part or process that’s not in the table there is a procedure for having it added. The standardized Cost Tables will be published through the FSAE website.
2. No Receipts – Since prices are standardized no receipts are required – except when requesting items be added to the table.
3. No Maximum Cost – You can spend as much as you like on your FSAE car with the understanding that your total cost is a significant factor in your Cost Event score.
FSAE Cost Guidelines
![Page 19: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/19.jpg)
2010 Cost Cost estimate for frame design consisting of
57 tubes and 114 tube ends
Material Costs:
- frame weight = 63.25 lbm
- standardized cost = $4.95/lbm
- material cost = $313.09
![Page 20: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/20.jpg)
Manufacturing
Standardized Costs:
Tube prep = $0.75/end
Tube cut = $1.20/end
Tube weld = $1.20/end
Tube bend = $0.75/bend
2010 Cost
![Page 21: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/21.jpg)
Manufacturing Costs
- 114 welds = $136.80
- 8 bends = $6.00
- 114 tube preps = $85.50
- 114 tube cuts = $136.80
- Total = $365.10
2010 Cost
![Page 22: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/22.jpg)
2010 Cost
Materials Cost = $313.09
Manufacturing Cost = $365.10
Total = $678.19
![Page 23: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/23.jpg)
Old VS New
Cost Reductions• Shorter Chassis• Less Manufacturing Costs
• More bends• Reduces the number of tube ends to be notched and welded• Bending is cheaper than cutting, prepping, and welding ends
![Page 24: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/24.jpg)
2009 ChassisItem Qty CostTube Cuts 130 $ 156.00Tube Prep 130 97.50Tube Welds 130 156.00Bends 4 3.00
Material Costs 306.90
Total Cost 719.40
2010 ChassisItem Qty CostTube Cuts 114 $ 136.80Tube Prep 114 85.50Tube Welds 114 136.80Bends 8 6.00
Material Costs 313.08
Total Cost 678.19
![Page 25: Concurrent Engineering](https://reader033.vdocument.in/reader033/viewer/2022061301/548ea5cbb47959454d8b45ce/html5/thumbnails/25.jpg)
Total Savings
$ 41.21~5.7%
Any Questions?