Next Gen FHSAE Engine



The purpose of this project is to design and manufacture a robust platform for testing and development on the next generation SAE car.

Problem Definition
Design a robust platform for testing and optimization of the next generation Formula SAE vehicle utilizing a KTM 540 motorcycle engine and a small frame drivetrain.

Background
The mechanical engineering department's Formula Hybrid car has been doing well in recent years at competition and now would like to experiment with the idea of venturing into the larger displacement and more competitive Formula SAE competition. This competition has major U.S. schools sending cars with full aerodynamics, carbon fiber frames, and budgets greater than $300k. Currently we do not have the backing to directly compete with these cars and their budgets, but we have shown we can design some very innovative and high quality components. This has encouraged us to try our hand at repackaging a KTM 525 motor into a few different configurations and showing our results at the national competition in hopes of gaining new funding and just impressing the competition.

Primary

 * •	Disassemble the KTM 525 engine and utilize Designworkz to trace complex geometry


 * •	Make detailed measurements using calipers and micrometers


 * •	Construct a CAD model of the engine in Solidworks


 * •	When drivetrain is procured, disassemble and obtain measurements for CAD modeling


 * •	Determine optimal drivetrain configuration for maximum efficiency

Secondary

 * •	Construct car frame and body in Solidworks around the optimal configuration


 * •	Utilize engineering analysis on engine, frame and drivetrain using computer models (MATLAB and ABAQUS) and hand calculations to guide design


 * •	Manufacture/Procure materials and parts to create final product

Specifications

 * •	KTM engine must be modeled as accurately as possible


 * •	Drivetrain must be realistic for engine size/capability


 * •	Frame design must be compact and lightweight


 * •	Several drivetrain configurations must be designed and compared to determine the balance between reality and efficiency


 * •	FSAE rules and regulations must be followed and factored into the design

Project Learning

 * •	Gain experience with 3D modeling of real world parts


 * •	Understand the complex workings of a highly refined engine


 * •	Adapt and re-engineer sections of the engine and transmission to work with the updated design


 * •	Understand the changes that need to be made based on experience from the hybrid engine

Progress