LeTourneau University Formula Team

2007 Chassis Fabrication Pictures

2007-02-12T16:39:00.000-08:00

2006-07 Formula Team Fabrication Update

2007-02-04T13:26:00.000-08:00

This year the chassis team consists of two senior Mechanical Engineering Technology majors, Todd Knallay and Ryan Reynolds. Todd has focused on the design and fabrication of the chassis frame and Ryan has focused on the pedal assembly and steering.

The chassis frame, while keeping the same basic geometry and increasing the rigidity from last year, is expected to weigh only 62 lbs, which is about 15-20 lbs less than previous LETU frame designs. The chassis was designed using a FEA software to optimize the design for low weight and high rigidity.

The pedal assembly has been changed from a floor mounted system to a top mounted assembly which results in a lighter assembly that is easier to adjust. The steering geometry was reworked to fit the slightly different suspension geometry and new kingpins.

Things are looking bright in the Machine Design Lab as the team is assembling the chassis.

Josh Stralow deposits a high quality weld using the Gas Tungsten Arc Welding process.

The late nights continue as the chromolly space frace begins to take shape.

Todd Knallay precision grinds a tube joint to perfection.

All of the main components are ordered and already starting to pour in. There is so much work to be done as the team prepares to build another car.

2006-07 LeTourneau Formula Final Design

2007-02-04T12:35:00.002-08:00

The 2006-07 Formula SAE car is a solid design, optimized for weight, cost, manufacturability and packaging, keeping with the original goals of designing a high performance prototype race car. It uses a 4130 chromoly tube frame chassis which meets the torsional rigidity specifications necessary for optimal performance. The suspension geometry is a push-rod/bell crank system implemented in both the front and rear. A one-piece kingpin was designed to create a better and stronger system. Our engine will again be a Honda CBR 600 f4i inline four cylinder engine with a custom designed exhaust and intake. The power will be transferred to the Torsen T1 limited slip differential mounted directly to the engine via a set of sprockets and 428 chain, then from the differential to wheels through Taylor Racing axles and a set of C.V. joints. Our car’s estimated total weight, without the driver, is 497 pounds. This accounts for all purchased parts and includes estimated weights of every component.

This design has decreased manufacturing complexity by minimizing the number of re-designed parts. This can be mostly attributed to last year’s car, which made a huge step toward a great design. Also, the packaging has been carefully considered, brackets drawn, and fasteners modeled in order to minimize, if not eliminate, interference problems that commonly arise during fabrication. All of this planning has also allowed our team to keep the center of gravity as low as possible.

In order to minimize weight, stress analysis was performed on every major component. A general safety factor of 1.2 was used for the design of most components, while a larger safety factor was used for critical components such as the kingpins and a-arms due to their dynamic loading and to ensure they do not fail. The defined maximum loading used was a 3.5g bump acting on the tire, and a 3.5g lateral load. This would relate to a worst case scenario of full cornering at a maximum speed with a sharp impact, such as a large bump.

God has provided received donations accounting for approximately $9,080, and promises of $5,500. This figure does not include the promised donated machining, parts, supplies, and other miscellaneous services. This blessing of funds enables us to order some of the required purchased components before leaving for Christmas break in order to prevent delay in the spring semester.

The intent was to design and build a high performance, well packaged, low weight prototype race car and the result of this fall semester has placed us well on our way. We are excited about starting construction of our design and plan to produce a car which will place well at competition and can be continued to be used as a solid starting point for future teams. With God’s continued blessing and a team that continues to be committed, we are confident this can be accomplished.

2006-07 Formula Team

2006-12-05T16:45:00.000-08:00

Left to Right: Jonathan Chapin, Jonathan Eriksen, Kevin Haveman,
Sam Coates, Todd Knalley, Josh Stralow, Ryan Shaffer, John Morrison,
Adrienne Cedargreene, Ansel Bodine, Josh Hughes, Phil Biggs,
Dr. Tom Hellmuth, Derrik Holmes

2006-07 Team Goals

2006-12-05T16:24:00.000-08:00

Provide an opportunity for team members to test technical skills, creativity, and an understanding of the design process to be carried over into industry.

Reduce vehicle weight from 550 to 480 pounds.

Finish in top 15 teams overall at the SAE competition in May, 2007.

Raise $22,000 to finance the endeavor.

Glorify God in all aspects of the project including the design, production, presentation, and competition.

LeTourneau University

2006-12-05T16:04:00.000-08:00

LeTourneau University is named for our founder - R.G. LeTourneau. While flying over the area in 1946 to select a manufacturing site, Mrs. LeTourneau saw the sprawling complex of a vacated Army hospital consisting of over two hundred frame buildings. When told that it was no longer in use, she asked about establishing a school to serve the many GI's returning from the war. The site was secured and LeTourneau Technical Institute was established. Since then LeTourneau Technical Institute has become LeTourneau University, a SACS and ABET accredited, nondenominational Christian university, offering four year and two year degree programs in engineering, technology, the liberal arts, business, aeronautical science, education, and the sciences, plus master's degree programs in business. Today LeTourneau is led by its President, Dr. Alvin O. ("Bud") Austin, and its Board of Trustees.

To learn more about LeTourneau University visit the LeTourneau University website.

2004-05 Formula Team

2006-11-29T19:46:00.000-08:00

2004-05

Competed in Pontiac, Michigan

2005-06 Sponsors Thanks!

2006-11-29T16:29:00.000-08:00

Racing Team ($3,000+)

Pit Crew ($1,500-$2,999)

Andy's U-Pull-It Auto Salvage

Fan Fare ($500-$1,499)

Bill Munday Motors Austin, TX
Greene Trucking Inc NY

Lodestar Logistics Corp Houston, TX

Finish Line ($1-$499)

Gregg County Oil Co

Turley Land Surveying Whitehouse, TX

Service and Product Donors

Alli’s Collections

Automotive Specialties

Caldwell Machine and Gear Mt Pleasant, TX

of Longview

About the Competition

2006-11-29T07:46:00.000-08:00

For our engineering senior design project, we are designing and fabricating a small open-wheel racecar to compete against 139 other colleges and universities at the Formula SAE event in Romeo, Michigan May 16-20, 2007. Recently, a Formula SAE West event has been scheduled for June 13-16, 2007 in Fontana, California; however, we have not yet planned to participate in this event. Formula SAE events are hosted by the Society of Automotive Engineers (SAE) and volunteers from the automotive industry are responsible for the running and judging of the competition.

The competition includes both static and dynamic events, and a total of 1000 points can be earned as shown:

Static Events (325 points)
Presentation (75 points)
Engineering Design (150)
Cost Analysis (100)

Dynamic Events (675 points)
Acceleration (75)
Skidpad (50)
Autocross (150)
Fuel Economy (50)
Endurance (350)

Some of the general requirements include:
- Must be open-wheeled and open-cockpit
- Cost not to exceed $25,000 for prototype vehicle
- Maximum engine displacement of 610 cc
- Single throttle body & 20mm circular restrictor required on intake
- Suspension required with at least two inches of wheel travel
- Minimum 60 inch wheelbase
- Minimum 8.0 inch wheels

2005-06 Formula Team

2006-11-28T18:28:00.000-08:00

2005-06

Competed in Pontiac, Michigan

2003-04 Formula Team

2006-11-28T18:27:00.000-08:00

2003-04

Competed in Dallas SCCA race on May 16, 2004.

2002-03 Formula Team

2006-11-28T18:24:00.000-08:00

2002-03

Earned 57th place at Formula SAE event in Pontiac, MI.

2001-02 Formula Team

2006-11-28T18:12:00.000-08:00

2001-02

First LU team to compete in FSAE event.

Earned 12th place and Rookie of the Year.