BROWN UNIVERSITY

Division of Engineering

BROWNFSAE

Industrial Heat Treating

Pohl Spring WorksThis year, the Brown University FSAE Design This year, the Brown University FSAE Design Team has undoubtedly produced the fast-Team has undoubtedly produced the fast-est racecar in our fifteen year history. All the est racecar in our fifteen year history. All the knowledge and experience of years past is ap-knowledge and experience of years past is ap-parent in this design; a design which relies on parent in this design; a design which relies on effectively implemented simplicity to create effectively implemented simplicity to create a vehicle with breathtaking speed. The team a vehicle with breathtaking speed. The team drove this car to a highly respectable 25th drove this car to a highly respectable 25th place finish (out of 123) and we were thrilled place finish (out of 123) and we were thrilled to discover new depths of potential as we did to discover new depths of potential as we did so.so.

THE CARTHE CAR

As measured during the non-ideal conditions As measured during the non-ideal conditions of actual competition the BRV9 (Brown Rac-of actual competition the BRV9 (Brown Rac-ing Vehicle ’09) was able to accelerate from ing Vehicle ’09) was able to accelerate from 0-60 mph in 3.6 seconds and pull 1.25 lateral 0-60 mph in 3.6 seconds and pull 1.25 lateral g on the skidpad. The car weighed in at 452 g on the skidpad. The car weighed in at 452 lbs, a slight increase over the previous year’s lbs, a slight increase over the previous year’s model due in part to a change in rules.model due in part to a change in rules.

In many respects, the BRV9 is similar to the In many respects, the BRV9 is similar to the ’08 vehicle; rear chassis and suspension geom-’08 vehicle; rear chassis and suspension geom-etry, intake and exhaust runner lengths, and etry, intake and exhaust runner lengths, and

overall drivetrain layout all carry over from overall drivetrain layout all carry over from ’08. However, each system was thoroughly re-’08. However, each system was thoroughly re-examined with an emphasis on ease of manu-examined with an emphasis on ease of manu-facturing and production.facturing and production.The most apparent change to this years vehicle The most apparent change to this years vehicle is the change in front chassis and suspension is the change in front chassis and suspension geometry. A new competition rule which re-geometry. A new competition rule which re-quires a template to be passed from behind quires a template to be passed from behind the steering wheel to just behind the pedals the steering wheel to just behind the pedals required Caitlin Ashley-Rollman ’09 to com-required Caitlin Ashley-Rollman ’09 to com-pletely redesign the front chassis and suspen-pletely redesign the front chassis and suspen-sion. While the rule change was initially re-sion. While the rule change was initially re-garded with disdain by all, it did create some garded with disdain by all, it did create some much needed space in the footbay.much needed space in the footbay.

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President Titanium

SUMMER 2009 NEWSLETTER

2009 Competition Results

Overall 25th pl. 446 / 1000 pts.Endurace 22nd 105 / 300Economy 16th 30 / 100Autocross 23rd 81 / 150Acceleration 38th 45 / 75Skidpad 58th 10 / 50Design 62nd 45 / 150Cost 41st 71 / 150

Extrude Hone

RISDMr. and Mrs. Paul Sorensen

Mr. Jared SlucterMr. Saben Murray More information on the Formula SAE competition may be found on our website: brown.edu/fsae

The carbon fiber intake this year represents The carbon fiber intake this year represents the culmination of our recent advances in the culmination of our recent advances in fiberwork. After reexamining the airflow, fiberwork. After reexamining the airflow, Luke Angelini ’10 chose to switch from Luke Angelini ’10 chose to switch from a center-inlet to a log plenum for ease of a center-inlet to a log plenum for ease of manufacturability. His excellence in manu-manufacturability. His excellence in manu-facturing and attention to detail allowed us facturing and attention to detail allowed us to get a stunning 70 hp at the rear wheels, to get a stunning 70 hp at the rear wheels, an almost 50% increase over the ’08 vehicle.an almost 50% increase over the ’08 vehicle.

The BRV9 is visually more appealing than The BRV9 is visually more appealing than any previous vehicle, thanks to the assis-any previous vehicle, thanks to the assis-tance of industrial designer Ethan Ballwe-tance of industrial designer Ethan Ballwe-ber RISD ’09. The carbon fiber nose cone ber RISD ’09. The carbon fiber nose cone and asymmetric side pods are skillfully in-and asymmetric side pods are skillfully in-tegrated with the rest of the car. Combined tegrated with the rest of the car. Combined with the traditional red powdercoat and with the traditional red powdercoat and carbon fiber seat, this creates a sleek racing carbon fiber seat, this creates a sleek racing machine.machine.

The team finished the car almost two weeks before the com-The team finished the car almost two weeks before the com-petition, which gave us time to tune the car to its full po-petition, which gave us time to tune the car to its full po-tential. Mike Dezotell of Dez Racing was generous enough tential. Mike Dezotell of Dez Racing was generous enough to again allow us use of his dynomometer to fine tune the to again allow us use of his dynomometer to fine tune the performance of our Honda F4i. Once on asphalt, our high-performance of our Honda F4i. Once on asphalt, our high-ly adjustable suspension then allowed us to dial in neutral ly adjustable suspension then allowed us to dial in neutral steering through most of the turn. steering through most of the turn.

THE COMPETITIONTHE COMPETITION

The competition this year was The competition this year was again held at the Michigan Inter-again held at the Michigan Inter-national Speedway. Upon arrival national Speedway. Upon arrival it was overcast and drizzling (as it was overcast and drizzling (as per regulations) and remained so per regulations) and remained so for the majority of our four days for the majority of our four days there.there.

We passed technical inspection We passed technical inspection on our first attempt for the sec-on our first attempt for the sec-ond year in a row. This forms the ond year in a row. This forms the basis of what we hope will be a basis of what we hope will be a long-running tradition. With a long-running tradition. With a working car and all three stickers working car and all three stickers from the inspectors, we had noth-from the inspectors, we had noth-ing better to do than to return ing better to do than to return again and again to the practice again and again to the practice

pits. By the end of the competition the car had been in and pits. By the end of the competition the car had been in and out more than half a dozen times.out more than half a dozen times. The static events all went smoothly and the results may be The static events all went smoothly and the results may be seen above. However, the car really got its chance to shine seen above. However, the car really got its chance to shine in the dynamic events.The four races were driven by five in the dynamic events.The four races were driven by five drivers this year; the drag event by Luke Angelini and Eli drivers this year; the drag event by Luke Angelini and Eli Bashevkin ’11, and the skidpad by Caitlin Ashley-Rollman Bashevkin ’11, and the skidpad by Caitlin Ashley-Rollman

and David Brown ’11. Hector In-and David Brown ’11. Hector In-irio ’09.5, our “tame racing driver” irio ’09.5, our “tame racing driver” then joined Luke in the autocross then joined Luke in the autocross event, while finally he and Caitlin event, while finally he and Caitlin drove the BRV9 to a stunning fin-drove the BRV9 to a stunning fin-ish in the endurance race.ish in the endurance race.

Our performance in the autocross Our performance in the autocross on Friday placed us towards the on Friday placed us towards the end of the fast heat for the endur-end of the fast heat for the endur-ance race on Saturday. Morning ance race on Saturday. Morning showers left a wet track for the ma-showers left a wet track for the ma-jority of entrants, but the timely jority of entrants, but the timely appearance of sun dried the track appearance of sun dried the track off in time for our start. This gave off in time for our start. This gave us a nice advantage over all our us a nice advantage over all our competitors except those placed competitors except those placed in the final and slowest heat.in the final and slowest heat.

Vivette El Fawal ’’09 after herfi rst experience in the car

BROWNFSAESummer 2009 Newsletter

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Various components of the BRV9 before fi nal assembly

Our time in Detroit was Our time in Detroit was practically carefree - no last practically carefree - no last minute disasters or unex-minute disasters or unex-pected problems came up pected problems came up that could not be fixed with that could not be fixed with a small amount of innovation a small amount of innovation and an even smaller amount and an even smaller amount of work. This allowed us of work. This allowed us to focus on areas where we to focus on areas where we saw room for improvement. saw room for improvement. Unfortunately, the amateur Unfortunately, the amateur nature of our driving skills nature of our driving skills was our largest detriment, try was our largest detriment, try though we did to improve it though we did to improve it with our time in the practice with our time in the practice pits. pits.

THE TEAMTHE TEAM

This year’s team of nineteen This year’s team of nineteen showed dedication and com-showed dedication and com-mitment beyond anything that could have been asked. Within a few weeks of freshman recruitment we had a com-mitted group of new members ready and willing to learn; we knew that they would be around through Detroit. This enabled all of us, with minimal instruction or oversight, to move right ahead with building a racecar. Take the fol-lowing example:lowing example:

Late one spring night just Late one spring night just after 9 p.m. about a week before we planned to have the car on the ground, two or three members were sitting in the shop with nothing to do. They texted around for sugges-tions and got one back - put one wheel on the car (only the one was ready to go). Word of mouth got around and by 6:45 a.m. having worked through the night, fully half the team was sit-ting in Louis diner eating breakfast with the ting in Louis diner eating breakfast with the knowledge that a rolling chassis, including knowledge that a rolling chassis, including functioning powertrain, sat back in the shop.functioning powertrain, sat back in the shop.

The majority of this teams commitment may be traced back The majority of this teams commitment may be traced back to our team lead, Caitlin Ashley-Rollman. Throughout the to our team lead, Caitlin Ashley-Rollman. Throughout the

year she was a constant source of motivation and year she was a constant source of motivation and support who drove us all to heights we did not think possible. Congratulations are due to her and to our other seniors who are also moving on: Ethan Balwebber, Mike Chon, Vivette El Fawal, Mark Fuller, and Hector Inirio. We wish you luck with your future endeavors, and you will be

greatly missed.

BROWNFSAESummer 2009 Newsletter

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uitment we uitment we dy and willing to learn;dy and willing to learn; nd through Detroit.nd through Detroit.

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CFD analysis of theintake manifold

From left to right: Will Cheung, Morgan Walti, Ethan Ballweber, Luke Angelini, Mike Chon, Eli Bashevkin, David Brown, Elinor Fung, Nick Vina, Mark Fuller, Vivette El Fawal, Caitlin Ashley-Rollman, Vihang Mehta, Jon Kalow, Ian Hovander, Melissa Byun, Hannah Singer, Will Richards, Hector Inirio

2009 Vehicle Statistics

Power 70.5 hpWeight 452 lb.Weight Distribution 45F / 55RWheelbase 60 inDisplacement 599 ccTop Speed 93 mph0-60 mph 3.6 sec.Suspension SLA

THE FUTURETHE FUTURE

Looking towards next year there are Looking towards next year there are several changes which we planning several changes which we planning to implement. First and foremost to implement. First and foremost is a switch to the newer generation is a switch to the newer generation of Honda 600cc engine, the RR. of Honda 600cc engine, the RR. While slightly more powerful, this While slightly more powerful, this engine is notable for its reported engine is notable for its reported weight reduction over the F4i, a dif-weight reduction over the F4i, a dif-ference of almost 15 lbs. In order to ference of almost 15 lbs. In order to reasonably implement this engine reasonably implement this engine package it will be necessary to de-package it will be necessary to de-sign and install a dry-sump system. sign and install a dry-sump system. Also on the agenda is a complete Also on the agenda is a complete redesign of the suspension geom-redesign of the suspension geom-etry, which is already underway etry, which is already underway by Will Richards ’10. With these by Will Richards ’10. With these changes and more we hope to cre-changes and more we hope to cre-ate a more well rounded vehicle ate a more well rounded vehicle that shows as much improvement next year as we were able that shows as much improvement next year as we were able to accomplish this year.to accomplish this year. As mentioned earlier, our most promising area of improve-As mentioned earlier, our most promising area of improve-ment is in our driving skills. We plan to use the BRV9, this ment is in our driving skills. We plan to use the BRV9, this amazing vehicle which we have produced, to train all our amazing vehicle which we have produced, to train all our drivers up to a professional level this fall. With luck, this will drivers up to a professional level this fall. With luck, this will enable us to form a linear regression of our competition re-enable us to form a linear regression of our competition re-sults; having moved from 47th place last year, to 25th place sults; having moved from 47th place last year, to 25th place this year, we hope and plan to achieve a 3rd place finish next this year, we hope and plan to achieve a 3rd place finish next year (which would incidentally necessitate a -19th place fin-year (which would incidentally necessitate a -19th place fin-ish in 2011).ish in 2011). As always, we would never have been able to accomplish any As always, we would never have been able to accomplish any of this without the assitance of our many generous spon-of this without the assitance of our many generous spon-sors. We sincerely thank you for the services which you have sors. We sincerely thank you for the services which you have provided, and for the support which you continue to show.provided, and for the support which you continue to show.

On this note an exciting new opportunity has recently On this note an exciting new opportunity has recently emerged for us. Mark Donohue, the famed racecar driver emerged for us. Mark Donohue, the famed racecar driver and motorsport enthusiast, graduated from Brown in 1959 and motorsport enthusiast, graduated from Brown in 1959 with a degree in Mechanical Engineering. Were he alive to-with a degree in Mechanical Engineering. Were he alive to-day, this year would mark his 50th reunion. His friends and day, this year would mark his 50th reunion. His friends and classmates, along with the Brown Development Office, are classmates, along with the Brown Development Office, are considering the creation of an endowed fund, in his honor, considering the creation of an endowed fund, in his honor, to benefit our team.to benefit our team.

We are pleased that such an opportunity may be pursued, We are pleased that such an opportunity may be pursued, and look forward to the possibility of producing a racecar and look forward to the possibility of producing a racecar which will truly be worthy of his memory. which will truly be worthy of his memory.

David BrownDavid Brown______________________________________________________

Please go to our website for recent updates and photos:Please go to our website for recent updates and photos:brown.edu/fsaebrown.edu/fsae

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Th e team talks with students at Vartan Gregorian Elementary School in our continuing eff orts at educational outreach