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This work details the process employed to design the 2009 Cooper Union FSAE® suspension system, spanning the overarching design philosophy, configuration selection, analysis, fabrication, and implementation, while offering recommendations to those especially new to the field. The design methodology illustrated here provides a systematic approach to suspension geometry, material selection, packaging, and construction. Though this paper serves as a starting point for FSAE® suspension designers, it provides a succinct overview for those interested in general suspension design fundamentals. The design process began with the selection of a suspension configuration, geometries, and kinematics, which were driven in part by tire data, desired bulk vehicle dynamics characteristics, and overall geometric variability. The springs and adjustable dampers were then selected as the front and rear anti-roll bar properties were concurrently designed.

Manifold tuning has long been a critical facet of engine design and performance optimization. This paper details the design, analysis, and initial fabrication of a variable runner length intake manifold for a restricted 2003 Suzuki GSXR 600 engine. A series of analytical Helmholtz resonance calculations were first performed to assess the feasibility of such a system. A comprehensive CFD study was then performed using a combination of Ricardo WAVE® and Fluent® simulations. Custom software was developed to optimize restrictor geometry through fully automated CFD simulations whose results were investigated to determine the optimal transition for the intended flow characteristics. This resulting candidate geometry was then used with a variable intake design in a Ricardo WAVE® manifold dynamics model and was varied iteratively to yield an optimum final geometry.

A low-cost, high precision strain gauge data acquisition system was designed and implemented to aid in optimizing the design of suspension and steering members in an FSAE vehicle. The primary focus of the project was to capture load limits in A-arms, steering tie-rods, and toe control linkages and to extract the dynamic response of the suspension system when subjected to steady-state cornering and bump scenarios. These data are critical considerations needed to systematically and aggressively address suspension material selection and fabrication, vehicle dynamic response, and weight savings. In addition, the data from this system were intended to enhance the accuracy of imposed FEA boundary conditions, corroborate on-road system responses to simulated data, and provide a cost-effective, wireless alternative for a wide range of low-level electrical signals throughout the vehicle.

Predicting the effects of transient heat conduction in low-heat-rejection engine components have been analyzed by applying instantaneous boundary conditions throughout a diesel engine thermodynamic cycle. This paper describes the advantages and disadvantages of one-dimensional finite difference and two-dimensional finite element methods by analyzing simple and complicated geometries like diesel bowl-in pistons. Also the performance characteristics of plasma sprayed zirconia, partially stabilized zirconia, and a monolithic reaction bonded silicon nitride ceramic materials are discussed and compared. Finite element studies have indicated that the steep temperature gradients associated with cyclic temperature swings in excess of 400 K may contribute to the failure of ceramic coatings near the corner joining the surface of the piston and the surface of the bowl for bowl-in pistons.