Mechanical Engineering

Applications

When planning construction an

understanding of materials has to
be your starting point

As you design each part - ask yourselves

A)

What is the parts function?

B)

Which direction will forces be exerted?

C)

How much force will be applied?

A-Arm Example

Types o f M ateri a l s
M etal s
S teel

C om posi t es

A l u m i n um Ti t an i u m Fi b ergl a ss Lam i n ates C arb on fi b er P l a sti c s

O th er
C l o th

Fo am

Steel
A) Mild
- Easy to form
B) Tool
- Wear resistant
C) Stainless - Stiff, wear and
rust resistant
D) Chromoly- Strong but not
brittle
E) ETC.
All are weldable

Tie Rod

Aluminum
A) Cast
- Hard, wear resistant
B) 4043
- Soft, workable
C) 6063 T-6 - Aircraft grade,hard,
weldable
D) 7075 T-6 - Aircraft grade,
very hard, can be
machined but not
welded
E) ETC.

Aluminum Parts

Titanium
Titanium comes in different
degrees of hardness and
brittleness. It tends to crack
in the corners then rip.

Examples

Fiberglass

This material takes advanced

thought. You can make changes to it after
construction. However, changes not in the
original plan often create a reduction in
strength or a significant increase in weight.
We have found it difficult to use fiberglass and
prevent the resign from creating more weight tha
We would like. There are also dangers in
working with and breathing the components
used in this process.

Laminates
There are a number of possibilities in
this area. We have used corrugated plastic,
corrugated fiberglass (flooring from passenger
planes), and Reynolite (an aluminum and
plastic laminate used for signs). Another
laminate construction is wood. Boats, canoes
and home built aircraft use wood laminate
as a method of construction.

Carbon fiber
We have researched this possibility
and shied away from it. We feel:
A) It is excessively expensive
B) To design a structure you must
learn at a completely different
level the material and process
C) You must think through
EVERY detail in advance

Plastics
We have used .035 Lexan for a number
of applications. One of those being our wind
shield. We have also used it in our battery box.
It insulates the box while providing a visible
check of the batteries without removing the the
seal from the box. Lexan is pliable and easy to
work with. Canopy is another application.
Plastic has also been formed to produce our
lenses for our lights. This has been done by
having a laser harden resign in layers.
Stretch and shrink wrap is another option.

Cloth
In some locations spandex is useful.
This might be done where you want to
hinder air flow but allow movement.
Airplane cloth on the other hand
can provide reduced weight and allow
enough strength to with stand a mans
weight.

Airplane Cloth

Foam
Houston Mississippi is a great
example. The outer airfoil of their car
has been foam insulation for homes. It is
light weight and cuts the air well.
We have used foam to laminate,
providing a shape between layers to create
strength.

Construction Joining Methods

A)
B)
C)

Bolt
Rivet
Weld
1) Rosette
2) Spot
3) Seam

D) Fiberglass
E) Solder
F) Glue

Fastening Methods
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)

Velcro
Roll pins
Cotter pins
Hitch pin
Push pin
Zip ties
Hasps
Zeus
Caulk
Spirolox

Zeus

Chassis

Chassis Designs
A)
B)
C)

Monocoque
I Beam / C - Channel
Tubular
1) Round
2) Square
3) Rectangular
4) Extruded

SS I

SS I
Rolling

SS II

SS III

Chassis Considerations
A) Design each member to
perform its function
B) A triangle is the strongest
structure
C) Use struts or corner braces
to spread out stress and loads

Suspension

Suspension
Suspensions can very greatly. If
you are racing only at the track event you
can save the weight of suspension PROVIDED
your car has a low stable center of gravity.
On the road races that is not true. For those
races no suspension will make the car hard
to control, fatigue the driver, and tend to
shake the car apart.

Types of suspension might include the

following:
A) Double A-Arm
B) Go-Kart
C) Radius link solid axel
D) Trailing arm (motorcycle)
E) Rocker
F) Shocked fork

How can you provide shock absorption?

I think the ways are limitless. Let you minds
think outside the box. Here are but a few
suggestions:
A) Car, snowmobile, motorcycle, bicycle
4-wheeler, or airplane shocks
B) Elastimers
C) Springs
D) Budgie cords
E) A Piece of a tire
F) Use your imagination

Shocks

Steering
To do this properly you need an auto
steering development program.
We use A-Arm Pro.

(use last years breaking mishap as the example)

A-Arm Pro

Aerobody

A) How important is it?

B) What considerations might I need
to take a look at?
C) What shape is the best?

How important is it?

This, in my opinion, differs for different teams.
If you plan to play the role of the tortes it is not
real important to your racing ability. If you
plan to maintain a speed below 25 mph it will
not make a great difference. On the other hand
If you plan to run at faster speeds it is very
important. An additional consideration might
be sponsorships. I think the more sleek and
professional the car looks the more you car is
noticed and the better the exposure for your
sponsors. Which translates to easier fund raising

What considerations might I need to take

a look at? (in no particular order)
A)
B)
C)
D)
E)
F)

Frontal area
Shape (tear drop, wedge, etc.)
Stability (other vehicles, weather)
Planned speed
Height off of the ground
High / Low pressure areas

G)

(computer program)
Safety if impacted ( review later)

C) What shape is the best?

You will need to decide. If no other
factors existed a tear drop is considered
the most aerodynamic by most. You
do not want lift nor do you want down
force. The car should be as neutral
as possible.

Solar Body Shell

Handout

Look at your design with

Discriminating eyes
Consider the following. If an
impact or mechanical failure
occurred how would it affect
the driver, car and others?

Examples:
If a car impacted your design from the
side at 90 degrees would the driver be
safe?
Considering the height of car and truck
bumpers, what would be the results to
your driver if the breaks failed and they
rear ended a vehicle?

If your car were driving at 45 mph and

the left front tire and rim separated
from the car what might be the result?
If the front of your car impacts
something solid would it cause parts of
the car to shear of and pose a danger to
the driver?
If an impact occurred would it cause the
driver exit to become jammed to hinder
the driver from reaching safety?

Join halves

Added roll bar

SS VI
Crush Zones

Car designs of others