Improvement of the aerodynamic performance of the Formula SAE Car
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Date
2017
Journal Title
Journal ISSN
Volume Title
Publisher
University of New Brunswick
Abstract
The SAE (Society of Automotive Engineers) International Formula SAE program is an
engineering design competition for undergraduate and graduate students. Students enter as
a team to develop and construct a single-seat race car with the goal of having the best
overall design, construction, performance, and cost. The SAE team for the University of
New Brunswick will be competing in this competition in May 2017. To optimize the
performance of the car, the aerodynamics of the vehicle was addressed as a concept that
could be improved. Based on the background research and calculations that were
performed, it was decided that the best approach to improve the performance of the car was
to increase the downforce on the car by adding front and rear wings. Quantitatively
speaking, it was estimated that up to 1.2 s could be saved for every lap of the endurance
event with the addition of wings. To achieve that objective, a multi-element airfoil design
composed of an Eppler 420 for the main element and a NACA 4412 for the flap was chosen.
Both the front and the rear wings were analyzed using CFD to determine the optimal angle
of attack and the magnitude of the aerodynamic forces at play. The section lift coefficients
that were obtained were then made three-dimensional by taking into account the effects of
aspect ratio on the performance of the wings. Endplates were also placed on the wings to
increase the effective aspect ratio and therefore lift. The lift coefficient of the rear wing
was found to be 2.1 while the one for the front wing was 2.5. This meant that 43% of the
aerodynamic forces were placed on the front wheels. From a manufacturing perspective, it
was decided that the wings should be made of a fiber glass and epoxy shell surrounding a
foam core. The endplates would be made of 3003 Aluminum. Plywood sections would also
be placed inside the shell to provide additional support and allow for the joining of the
various components. The strength of all the parts was then determined by using empirical
data and performing FEA simulations. A scaled prototype for the design symposium of
each wing was also manufactured using a 3D printer. Although it was not possible to build
the wings during the course of this project, detailed drawings were made to allow the UNB
Formula SAE Club to fabricate them and add them to their race car.