The NUS Formula SAE (FSAE) team brings together the brightest and most passionate students from various disciplines to build and drive an electric Formula-style race car to compete annually against teams around the globe at the Formula SAE Michigan competition. Students who aspire to be part of the FSAE team need to complete a training programme before they are selected for the main competition team. This course is designed for the FSAE trainees to provide them with exposure to the basics of automotive engineering that are essential for building a race car.

At the end of this course, students should be able to:

• Understand the basic components and subsystems of a race car.
• Create prototypes of components and subsystems using appropriate fabrication methods.
• Adopt good technical documentation and housekeeping practices.

Workload: 4 units (graded on CS/CU basis)

Note: This course is only available for students who are selected for the FSAE training programme.

Course syllabus

Introduction to FSAE competition:

• Competition format
• Rules
• NUS FSAE team format
• Roles and responsibilities

Chassis:

• Function of chassis
• Different type of chassis
• Chassis loading
• Cockpit ergonomics
• Pedals, steering wheel, seat and harness
• Composite theory

Suspension:

• Function of suspension
• Different type of suspension system
• Tyre data
• Suspension geometry
• Suspension loading

Aerodynamics:

• Effects of aerodynamics
• Different types of aerodynamics devices
• Drag, lift and aerodynamics balance

Drivetrain:

• Introduction to gears and clutch
• Different types of drive
• Function of differentials
• Different types of differentials
• Different types of joints and half shafts

Electric drive:

• Control theory
• Different types of motor controller
• Different types of motor

Electrical and electronics:

• FSAE rules for electrical
• Basic schematics for FSAE cars
• Function of major subsystem in FSAE cars
• Basics of CAN bus
• Connectors, wire gauge and shielding

Engine:

• Different types of engines
• Introduction to wave dynamics
• Intake and exhaust
• Cooling and lubrication
• Forced induction
• Hybrid drive

Sensors:

• Different types of sensors on FSAE car
• Sensor calibration
• Introduction to datalogging

Race car reliability / failure:

• Material fatigue
• Force calculation
• Testing and validation
• Case study

CAD training:

• Basic SolidWorks training
• CAD good practices
• Design for prototyping
• Advanced SolidWorks training

Finite element analysis:

• Introduction to finite element analysis
• Ansys Static Structural GUI and setup
• Ansys Fluent GUI and setup
• Case study

Fabrication:

• Manufacturing methods
• Milling training
• Lathe training
• Composite training

Safety:

• Risk assessment
• Introduction to tools and equipment