Design and Analysis of a Drive Train System for a Small Race Car

The project is a design and development project of a drive train system for a
Formula-style race car. The main objective is to replace the current Universiti
Teknologi PETRONAS FSAE (Formula Society of Automotive Engineers) car chain
drive system to the gear drive system. The project was conducted with the target of
designing the systems for entering a Formula SAE competition and the design has to
abide withFormula SAE rules and regulations. This report focused on the design and
analysis processes of the drive train system using relevant vehicle dynamics theories
and formulas and heavily utilized computer aided engineering tools such as CATIA.
No modifications were allowed to the engine as well as the transmission (gear box)
due to limitations on the drive train. The design of the drive train was based on gear
sizing calculations as part of the car performance analysis. The results include the
determination of final drive ratio, maximum velocity, and idle changing gear speed
and also the reliability of the new drive train system, which is the gear drive system.
The assumptions for certain parameters such as coefficient of drag, frontal area, and
overall mass of the car was based on similar existing Formula SAE race cars in order
to begin with proper design calculations and performance predictions for the
designed race car. The designs of the drive train component including engine drive
shaft, bevel gear (ring and pinion), differential housing and bearing based on the
performance requirements and analysis. Finally, the report elaborates on the positive
benefits and gains from the project and some recommendations on potential
improvement and possible new designs