2017-2018 Season
New Member/Special Projects Engineer
I joined the FSAE team my freshman year and started off doing odd ball jobs for different project engineers through-out the team. As the semester progressed I joined the Powertrain sub group. I attended the weekly Powertrain meetings and was given multiple projects that I was in charge of.
Projects:
Oxygen Sensor Bung
Diffuser/Restrictor Tooling
Flow Bench
2018-2019 Season
Cooling Project Engineer
In charge of all aspects of the cooling system on the car. From the research and design to the manufacturing and validation.
Before design, testing of previous year's car was completed.
Radiator Inlet Air Temperature Sensor
1/6 Water Temperature Sensors
Using CFD to get Velocity of Air
Radiator Inlet Air Temperature Sensor
Design of the cooling system involved collaborating with several sub-groups and Alumni of the team. Once 3D modeled in Siemens NX, FEA's were completed to ensure system would not prematurely fail.
Final Product and Performance at Competition:
The team went to two competitions for the 2019 season, Michigan and Lincoln. During Lincoln endurance, the hotter of the two competitions, the maximum temperature of the engine was 112°C, which was a 17% improvement from previous competitions. This increase in cooling capacity allowed us to place 4th out of 76 teams.
2020-2021 Season
Chief Engineer / Vehicle Dynamics Lead
Managed a team of 18 project engineers and group leaders. Throughout the season I performed many design reviews with each project engineer and scheduled design reviews with alumni of the team.
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The team had the opportunity to attend Formula SAE competition in Michigan. With the following results:
3rd - Overall!
1st - Skidpad
3rd - Autocross
4th - Acceleration
8th - Endurance
Team Structure
Team's First Carbon Fiber Monocoque
This year the team is developing our first carbon fiber monocoque. This allows for new innovative designs to be implemented on a new platform.
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Through collaboration with the aerodynamics group, I was able to create a 3D model that performed well in CFD.
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Unfortunately we were unable to complete the monocoque prototype, but I have set up the machining of the mold to allow the 2022 team to be in a good position to take a monocoque to the 2022 competition as planned.
Team Management
Teams first year to use a dedicated Project management software, "Smartsheet."
This software allows us to have everything in one place including Gantt charts, contacts, and financial records.
Semi-Unsprung Aero
As chief engineer I also had some small projects I was in charge of, one being our car's semi-unsprung rear and front wing. Our car has ran this type of aero for several year, but with movement issues when driving.
Design
Starting with the rear wing, I sat down with the aero group to brainstorm ideas to cut down on lateral movement in high speed turning. The solution decided on was moving the lower a-arms to a more horizontal angle to contract the forces created during turning. Performing motion simulation and FEA's supported the theory.
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In the past the front wing had too much movement or acted as another roll bar, both are unwanted. To come up with a solution I started with brainstorming mounting solutions and narrowed it down to three options. For each of these options I created a 3D model and performed motion simulation to see the movement and make sure the wheels could act independently. From simulation the best option was chosen.
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Results
After assembly of the aerodynamics system, visual inspection was performed of the rear and front wing mounting. I was very pleased to see the results, very little lateral movement from the rear wing and the front wing allowed each wheel to act independently while maintaining rigidity.
Drag Reduction System (DRS)
Another project I was in charge of was designing the DRS for the car's aero system. DRS has been attempted in previous years of the team, but never successfully implemented at competition.
Design
It was decided to use DRS only on the rear wing 2nd and 3rd elements due to them being high drag producers and the possibility of implementing. Using angle of attack numbers given to me by the aerodynamics team, I used MATLAB and 3D simulations to design the system.
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Results
After in depth testing, I am happy to say that I was able to design and build the first ever DRS for our car. It was able to go from low to high drag in under 0.2 seconds.