The major assignment for the unit is to design the final drive for the F-SAE race car. This is a group project to be completed with groups of up to 5 people. The design should be ready for manufacture by the end of the semester. The final drive that includes the final gear pair and differential housing, hubs and bearings, is intended to be the design for the next several years. The final gear pair must fit the existing output shaft of the engine, the differential must accommodate existing differential internals, the differential hubs must accommodate the existing tripod CV joint and the entire assembly must fit within the supplied envelop.
The assignment deliverables for the final drive assembly are as follows:
1. A complete set of design documents for the final drive assembly:
? A design report that details (30%):
? Market research
? Product design specification
? Concepts and evaluation
? Manufacturing details (including timeline)
? Cost estimates
? An analysis report that covers (30%):
? Load calculations
? Strength and stiffness calculations
? Finite Element Analysis of component(s)/assembly where applicable
? A complete set of manufacturing drawings (15%)
? SolidWorks 3D model of the final drive assembly (10%)
2. An informal 5-10 minute presentation of your group’s final drive assembly design to the class during the final lecture (5%).
The final 10% of the mark is based on report quality, such as grammar, referencing, presentation, etc. The written component of the design report should not exceed 20 pages, any content beyond 20 pages will not be considered in the mark. The analysis report should not exceed 20 pages, any content beyond 20 pages will not be considered in the mark.