LYNX MOTORSPORTS FSAE
Overview
The 2021 Car utilizes a stock CBR600 engine with an aluminum fuel tank, intake and oil pan. The engine runs e85 fuel and is tuned with MoTec M130 ECU for EFI systems. Data logging is handled by a MoTec C125 dash connected via CAN-bus with the MoTec ECU and Power Distribution Module.
The frame is a steel spaceframe designed with a short wheelbase to improve cornering ability and minimize weight while retaining enough space for 6’2” driver and the CBR600 Engine.
The suspension is direct actuation in the front and indirect in the rear utilizing Ohlin TTX-25 MKII Dampers. The 10’ tall and 7.5’ wide Hoosier LC0 is the tire of choice, paired with 10" center-lock OZ Magnesium wheels.
The aerodynamics package consists of an undertray, front and rear wings.
Business Presentation (Scope)
Chassis
Originally developed in 2019, the chassis was to reduce the previous years' by triple digits. Unfortunately, COVID stagnated the progress thus leading to a complete redesign for 2020. Manufactured, welded, and designed in house.
Goals
Manufacture a steel chassis designed to protect the driver and withstand the rigors experienced within the scope of the FSAE motorsport competitions, accommodate suspension overhaul, 10% less weight than 2019 Car with lower CG, and improve upon mistakes learned from previous teams.
Design
Basic drafts started with the suspension/tire mounting geometry chosen from our OptimumK simulations along with wheelbase considerations, total lengths and heights were adjusted to satisfy rulebook height requirements (roll hoop angle, driver height allowance, interior templates). Including the engine, pedal box, differential packaging. Proper triangulation at nodes and tube diameter to meet SES.
Manufacturing
Tube profiles were cut and coped by VR3 , jigging templates were machined on a 4’x8’x3” cnc router to simplify fixturing, tubes were fixed to our welding table and over the course of several days all tubes were tacked and welded. Various methods of aligning and measuring was done to carefully construct a straight and square frame.
Competition
With a complete aero package, our car was the first to complete the endurance event (46 laps) with out a breakdown. CU Denver placed in the Top 20 out 50 schools that got compete in the event.
Insights Gained
The biggest success has been in-house manufacturing. This leap has allowed me to become familiar with CNC, composite, fabrication, and additive techniques- and ultimately gain a deeper understanding of manufacturing processes across several specializations.
The structure of the team has shifted significantly over the last year. The leadership roles have mainly been reserved for senior students but with a lack of students returning during the pandemic, underclassmen (such as myself) had to step up.