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Project Summary
This culminating project at Thayer School was a team effort. This Formula Society of
Automotive Engineer (FSAE) racecar was entirely designed and built by the 2006 team. My sub-team was primarily concerned with
the vehcile dynamics of the car as well as creating an Anti-Roll Bar package.
Complete 2006 DFR Assembly
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Fall 2005 - Present
Class Project / Academic Team / Club
Engineering Programs/Methods Used:
- Pro-Engineer
- Pro-Mechanica
- SusProg3D
- Thayer School Machine Shop
- Shock Dynamometer
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Front Assembly
Rear Assembly
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Deliverables:
- Complete comparative analysis of 2005 and 2006 cars, including frame strength and stiffness
parameters, cg, etc.
- Optimized shocks and springs for the 2006 car
- Rocker arms optimized for shocks, springs, and suspension geometry
- Optimized anti-roll bar packages
- Alignment jigs, suspension tuning tools
- Documented process of suspension tuning strategy using data provided by the data acquisition
system
- Accurate Pro/ENGINEER drawings of all parts
- Cost report for all purchased and manufactured parts.
- Proposal, progress, and final reports documenting the design, manufacture, installation,
and performance of all systems
- Detailed recommendations for 2007
Vehicle Dynamics Team
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Project Detail
A major part of our project was to design
and build the front and rear bellcranks used to support the entire suspension system of the car. Our team used suspension
design software, SusProg3D, to design the geometries of the bellcranks. The entire anti-roll bar package that we designed,
which we are now in the process of implementing on the 2006 Dartmouth Formula racecar, will help improve the cornering efficiency
of the car by transferring some of the lateral loads applied to the wheels of the car in bump and droop situations.
Vehicle Dynamics Complete Assembly - Anti-Roll Bar Package
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Front Anti-Roll Bar Package
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Rear Anti-Roll Bar Package
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Manufactured Front Bellcrank
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Manufactured Rear Bellcrank
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Shock Tuning
An exciting new endeavor that our team took
was purchasing shocks specific for our car's size. In the past bicycle shocks had been used and time after time had not performed
well. We were also the first team to revalve our shocks to meet team set specifications. The revalving scheme shown below
displays the black carbon fiber shims and washers necessary to change the rebound and compression characteristics of our shocks
to meet the team's needs.
Our shock revalving scheme
Candi, the 2006 Dartmouth Formula Racecar assembled.
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Final Front Assembly
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Final Rear Assembly
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Candi, ready to compete at the FSAE competition in Detriot, MI.
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