LEARN & COMPETE SUMMARY
Volume 1, Team Organization and Design
Chapter 1, Formula SAE Basics by David Gould
As the title suggests, Mr. Gould outlines the basic steps that need to be followed by a Formula team.
Chapter 2, Team Organisation by Michael Royce
The author outlines some basic principles of team organization and structure that have worked for him in his many years of being an engineering manager.
Chapter 3, Project Management by Michael Royce
Mr. Royce has said many times that Formula competitions are more about project management than engineering! In this chapter, he outlines the steps that teams should follow to compete successfully at the competition.
Chapter 4, Knowledge Transfer by William C. Mitchell
As Mr. Mitchell notes, the key to teams improving year by year is passing on the successes and failures from year to year, i.e., “knowledge transfer”. He provides tips on how to achieve this seemingly difficult task.
Chapter 5, Sponsorship by Suzanne and Michael Royce, based on material from Adam Zemke
Without sponsorship, most teams would not exist or survive! This chapter looks at the “What’”, the “Who”, the “Where” and the “How” of obtaining and retaining sponsorship.
Chapter6, The Design Process by Anthony Lyscio
Designing a Formula car is a complex process. Mr. Lyscio outlines a process and addresses a couple of the “big decisions” teams will need to address along the way.
Chapter 7, Aerodynamics by John Bucknell and Michael Royce
Aerodynamics have recently become much more important in Formula competitions. To become an expert takes many years of study and application. Hence, this chapter is only an introduction into the terms and basic principles involved.
Chapter 8, Ergonomics, by Michael & Suzanne Royce and Michele Grimm
To extract the most from a car, the driver must be comfortable and “at one” with the car. Hence, ergonomics are important. This chapter outlines some of the items that must be considered, including passing the “Percy” test.
Chapter 9, Cockpit Control Forces by Steve Fox
Mr. Fox gives some very important data on the forces exerted by the driver that can and/or should be considered in the car’s design.
Chapter 10, The Frame and the SES by Dan Jones and Michael Royce
This chapter gives some basic information on steel tubing and then gives detailed guidance on filling out the original SES. FSAE has changed the SES format, but the basics remain the same. It also gives some tips on the design and build of a tube frame chassis.
Chapter 11, Suspension and Steering - The Basics by Douglas Milliken and Edward Kasprzak
Like many areas of car design, steering and suspension design is a life-long learning experience. This chapter should be the starting point for any steering and suspension engineer.
Chapter 12, Dampers by Jim Kasprzak
After reading Mr. Kasprzak’s chapter, a student should have a good, basic knowledge of dampers upon which to build his/her own experience.
Chapter 13, Tyres by Edward Kasprzak and Douglas Milliken
The tires are the starting point of suspension design. Messrs. Kasprzak and Milliken explain some of the basics and where and how the Formula SAE Tire Test Consortium fits in to the picture.
Chapter 14, Racing Brake Systems by Mike O’Neil
Mr. O’Neil gives a detailed explanation of how the various brake components work and then outlines a process for the design of a Formula car brake system.
Chapter 15, Vehicle Simulation by Edward Kasprzak and Douglas Milliken
Vehicle simulation is becoming more common with Formula teams and is often mentioned at the Design Event. Messrs. Kasprzak and Milliken outline some of the uses and pitfalls involved.
Chapter 16, Powertrain General by John Bucknell
In this chapter, Mr. Bucknell tries to give students a basic understanding of the terms and other considerations used in engine design and development. He also touches briefly on the transmission and final drive.
Chapter 17, Engines by Michael Royce
Mr. Royce gives his opinion on IC engine selection and some of the challenges facing teams with their engines.
Chapter 18, 1D Engine Modelling Basics by Mark Claywell
Mr. Claywell gives a very good primer on 1D engine modelling and how teams might benefit from the use of one of the commercial software packages that are available.
Chapter 19, Engine Ancilliary Systems by Michael Royce
This chapter touches on the work that needs to be done on the throttle, intake, exhaust, cooling and fuel systems not only from athedesign aspect but also from the perspective a passing scrutineering (technical inspection).
Chapter 20, Electrical Systems Integration by David Redszus
Using the development of integrated vehicle electrical systems development as an example, this chapter illustrates many of the product development management issues that teams and their leadership should be aware.
Chapter 21, Driver’s Safety Harness. The Selection, Installation and Care
This chapter details the choice, installation and care of one of the most important safety systems in the car.
Chapter 22, Weight by Michael Royce
The author gives his thoughts on how teams should handle weight.
Chapter 23, The Bill of Material-BOM by Michael Royce.
The BOM is the “bible” that goes with the design drawings or CAD and is one of the outputs of a Design Department. It is often overlooked and neglected by Formula teams. This chapter gives some thoughts on how to construct and read a BOM.
Volume 2, Car Build, Test & Development and the Competition
Chapter 1, Car Fabrication, Machining by Steve Fox
This chapter covers a good variety of basic and innovative machining processes, specifically targeted at students with typical college machine shop resources.
Chapter 2, Car Fabrication, Machining and the Hard Parts by Steve Fox
In this chapter, Steve Fox covers what teams consider the most challenging parts to manufacture, the uprights. He also includes a “bullet-proof” method for bonding ends into composite tubes to make control arms and pushrods.
Chapter 3, Welding by Carl Occhialini
This chapter covers the basics of welding, an important skill at which all Formula teams need to become proficient.
Chapter 4, Threaded Fasteners by Michael Black
Threaded fasteners (nuts, bolts and studs) are used across a range of components on your formula car to assemble it into a unified machine. This chapter covers several major factors that influence joint reliability and is intended as an aid in joint design, fastener selection, and installation.
Chapter 5, Test Planning and Organisation by Michael Royce
This chapter gives some suggestions on the types of testing a team should undertake, and tips on test planning and equipment.
Chapter 6, Data Acquisition by Frank Whiton
The author gives some tips on what to look for in the choice of a data acquisition system, on sensors, on test planning and on data interpretation.
Chapter 7, Powertrain Controls Development and Calibration by John Bucknell
The author outlines, step-by-step, the process for calibrating an IC engine, without which a team is doomed not to succeed at the competition.
Chapter 8, Torsional Testing by Phil Morse
A torsionally stiff chassis is the base upon which all suspension performance relies. This chapter outlines the theory and procedures for measuring the torsional stiffness of a formula car’s chassis.
Chapter 9, Suspension Development and Tuning by Darrell Hancock, Jr.
In this chapter, the author gives further tips on the development process and includes suggestions on suspension development.
Chapter 10, Chassis Development and Suspension Tuning by Steve Lyman
More tips on chassis and suspension development and tuning with a focus on the tires and damping.
Chapter 11, The Design Event Submissions, The Design Specification Sheet and The Design Report by Pat Clarke
The Design Judges use these two reports to become familiar with the team’s project before arriving at the competition. Pat Clarke outlines what the judges are looking for.
Chapter 12, Three View Drawings by Steve Fox and Edward Kasprzak
The Design Report requires the teams to include three view drawings of the vehicle. This chapter outlines what the judges are expecting to see.
Chapter 13, The Impact Attenuator, Testing and the Impact Attenuator Data Report by Michael Royce
This chapter gives the background of the IA and IAD reports. While many teams now use the “standard” FSAE IAs, those who still design, build and test their own need to avoid some common mistakes.
Chapter 14, At the Competition by Suzanne Royce
In the excitement and rush to get to the competition, some things can easily be overlooked and forgotten. This chapter is especially meaningful for young teams as to what happens when they get there, and lays out the normal timetable at the competition.
Chapter 15, Getting Through Mechanical Technical Inspection by Suzanne and Michael Royce
This chapter gives a very detailed list of what the inspectors are looking for at Mechanical Technical Inspection.
Chapter 16, Passing Electrical Technical Inspection by Paul Messier
Some tips on passing electrical technical inspection.
Chapter 17, The Design Event by Pat Clarke
Pat Clarke outlines the Design Event format and scoring and gives some tips on how to prepare for the Event and on how to present the team’s design to the judges.
Chapter 18, The Cost Event by Michael Royce
While the Cost Event is the most unliked event at the competition, the author outlines its importance, and how to maximize the points a team accumulates at this event.
Chapter 19, The Business Presentation Event by John Saville
Although the premise and format may change from competition to competition, good preparation and practice are vital to score well in the Presentation Event. The author gives tips on what it takes to succeed.
Chapter 20, General Safety by Michael Royce
Various aspects of safety have been covered in some of the previous chapters. In this last one, the author covers many of the others including driver’s gear, and getting to the event (trailer choice and loading).
