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Front Wing Mounting DRDR

Keiji Imai

3/12/23

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DRDR Agenda

  • Part Scope
  • Lessons learned from previous cars
  • Rules
  • Design Requirements
  • Timeline
  • Appendix

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Part Scope

  • Increase car performance
    • Support front wing which increases downforce
  • Attaches frame to front wing
    • Interfaces with frame tabs and front wing plates
  • Inputs: Forces applied by front wing, mounting locations
  • Outputs: Deflection under load
  • I need help with determining loads and doing hand calcs and FEA

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Lessons learned from previous cars

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MY19

MY20

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Lessons learned from previous cars

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  • Needed to weld tabs while car is on the ground and spring stiffness is set to get the right ride height (MY20)
  • Difficult to remove front wing (MY18, MY20)
  • Dovetails are difficult to machine
  • Endplates are structural in MY20 design, increasing weight

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- Stefan

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Lessons learned from previous cars

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Wasim’s CAD

Alex’s proposed design

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Rules

TLDR:

  • No excessive front wing oscillations while car is moving
  • No sharp edges

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TLDR:

  • Don’t use space above +/- 75 mm from the wheel

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More rules

TLDR: Don’t let front wing touch the ground

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TLDR:

  • Don’t use space above +/- 75 mm from the wheel

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More rules

TLDR: Stay within shaded area

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TLDR: Stay within shaded area

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More rules

TLDR: Can’t mount in front of Anti Intrusion Plate

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TLDR: Less than 25 mm deflection under 200N

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More rules

TLDR: Front wing cannot cause deceleration faster than allowed

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TLDR: Need to test or calculate force required to crush front wing

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Design Requirements

  • Rules legal + pass SES
  • Mount to frame and front wing
  • Don’t interfere with nosecone
  • Under .75” maximum deflection at 300N
  • Geometry while turning and suspension maxed out
  • Yield strength 1.2 factor of safety
  • Machinable in-house (waterjet + haas)
  • Removable without taking off nosecone
  • Less than 0.2 kg
  • Fails at peak impact attenuator load

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Timeline

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Week

March

April

May

1

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Fix design and do hand calcs

Weld tabs and assemble

2

DRDR

DR1

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3

Initial design and FBDs

Run FEA and improve design

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4

CoDR

Machine parts

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Appendix

Throw in any supplementary material here.

MY20 Front Wing Mount FEA

Engineering Requirements

Design review templates

FSAE Rules

Aerodyne DR Slides

Aerodyne Meeting Notes

Current state of aero

Front wing + Diffuser Mounting Google Doc

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