2012 Formula SAE- Outboard Suspension -

Team:Carole Gayley Jose Colin

Chip Larson Josh McCall Efe Yıldırım Rick Rickert

Industry Advisor: Even Waymier

Overview• General Info

• Mission Statement• PDS• TRM

• Questions

General InfoEvery year the Viking Motorsport team

designs and builds an open wheel racecar using a 600cc engine and

competes in an international competition held in Kentucky.

Mission StatementThe mission of theOutboard Suspension teamis to improve the design of the hub and upright by reducing machine time and cost, while decreasing weight, and decreasing rolling resistance in the bearings.

Product Design SpecificationPerformance

Priority Requirements Primary Customer

Goal Metric Target Target Basis

Verification

4 Hub weight FSAE Team Decrease weight Pounds 2lb Customer defined

Prototype

ManufacturingPriority Requirements Primary

CustomerGoal Metric Target Target

BasisVerification

4 Ease of hub manufacturing

FSAE Team / manufacturing

Decrease complexity

Machining time (min)

80 minutes Customer defined

Prototype

Product Design SpecificationLife in Service

Priority Requirements Primary Customer

Goal Metric Target Target Basis

Verification

2 Service life FSAE Team / driver

Ensure sufficient reliability

Operating life (years)

Minimum 5 year life

Customer / group

FEA / prototype

DisposalPriority Requirements Primary

CustomerGoal Metric Target Target

BasisVerification

1 Recyclable Material

FSAE Team Minimize Disposal Cost

N/A N/A Customer Defined

MSDS

Product Benchmarking

2011 VMS Outboard Suspension• 3.1 lb hub weight, 120 minute hub machining time, $200 hub cost, 4 lugs

2010 VMS Outboard Suspension• 4 lb hub weight, off the shelf Volkswagen product, $35 hub cost, 4 lugs

Taylor Race Engineering Outboard Suspension• 4 lb hub weight, off the shelf product, $389 hub cost, 4 lugs

2012 Design Target• 2 lb hub weight, 80 minute hub machining time, $200 hub cost, 1 lug

Technical Risk Management- Risk Identification -

• The team is unable to deliver on time•The parts are improperly sized•The parts cost too much to make

Technical Risk Management- Risk Assessment -

Frequent Likely Possible Unlikely Rare

Catastrophic Extreme Extreme High High Moderate

Severe Extreme High High Moderate Low

Marginal High Moderate Moderate Low Low

Negligible Moderate Low Low Low Low

Missed delivery date Parts undersized Parts cost too high

Technical Risk Management- Risk Mitigation -

• Delivery time• Timelines for the project have been developed to keep the project on schedule - Reduces Likelihood• Maintain ability to use previous years parts - Reduces consequence

Technical Risk Management- Risk Mitigation -

• Parts Undersized• Detailed FEA and engineering practices are used to size parts - Reduces Likelihood• Extensive on vehicle testing starting at low speeds to validate parts - Reduces consequence

Technical Risk Management- Risk Mitigation -

• Part cost too high• Keep part features simple and easy to machine - Reduces Likelihood• Ensure parts are designed correct the first time so duplicates don’t have to be made - Reduces consequence

Technical Risk Management- Risk Monitoring -

• Watch timelines to ensure project is on schedule• Carefully monitor the vehicle during first runs to ensure parts are strong• Get cost quotes before the parts are made and talk with the machinist to find areas to decrease cost

QuestIons?