Blog Post #5

Figure 1: Near-Complete Weld Bead on Bias Bar Sleeve

Figure 2: Screenshot of FSAE Cost Report System

Over the work period of March 20 - April 3, the shop has been shut down so access to work on the project has been restricted. Prior to the shutdown, most of the welding around the bushings and bias bar sleeve was completed on the brake pedal. The image displayed in Figure 1 is of the brake pedal prior to the bias bar sleeve weld-bead being completed. With the bias bar sleeve and the bushing welds completed, the middle support straps can be prepared for welding. It is worth mentioning that welding on the top plate has been completed as well. The MMI team has been working on competition paperwork and was able to complete the cost event report. The cost report details the cost for every part needed to build the project. This includes the materials, manufacturing, and process costs. A screenshot from the cost report system the MMI team used to generate the report is shown in Figure 2. The value for made parts was calculated based on a database of materials, processes, and fasteners provided by FSAE.

Before the Stay-at-Home order was issued, the team was able to leave some steel and aluminum parts with a welder from Cougar Racing. This has allowed some fabrication to be continued during this time of shutdown. The MMI team has been formulating a plan to move forward with the project amidst the closure of the shop. The team, with the guidance of Dr. Chen, has decided to propose a change to the validation of the project. The new validation will consist of a detailed FEA of key components like the brake pedal and the master cylinder mounts. The new analysis will take the place of physically testing these parts on the Instron machine while still verifying the design will perform sufficiently under the maximum load conditions required for competition. The MMI team will not be able to do any physical work or validation due to the physical position of the team members and the closure of the shop. Each member of the team has been assigned a role in order to ensure the progress of the project.

Charles Raper and Omar Arreola are currently working on generating simulations using the SolidWorks and Fusion 360 FEA tools respectively. Carrie Kauffman is in touch with the President of Cougar Racing and helping work out details on how the MMI team should proceed with our work as a whole up to competition. Henry Huynh is currently assisting with setting up the simulations and will be providing quality control on the FEA. When the simulations have been run an adequate number of times and the models have been checked for errors, work will begin on the final technical reports for Capstone 2.