Momentum - April 2019 - 8

FEATURE

STUDENT
GENERATION

FULL CIRCLE
UT05 showing off precious "medals" after
winning Formula Student UK in 2005.

Over its 21-year history,
the University of Toronto
Formula Racing Team's chassis
department has left no stone
unturned.
AT THE END OF A LONG ALLEYWAY in an obscure
quad lies one of the older buildings on the University
of Toronto's downtown campus. In stark contrast to the
glass-walled glamour of the new campus buildings that
rise around it, it's hard to believe that this complex was
once home to an experimental nuclear reactor. For the
past 17 years, the University of Toronto Formula Racing
(UTFR) team has made home of a workshop in the
corner of the secluded Haultain Building.
The awards that adorn one wall of the office space
remind our current team members of their predecessors'
success. Until just three years ago, our team was proud
to hold the record for the most overall wins at Formula
Student UK. While UTFR has succumbed to the challenges
of knowledge transfer and wavering membership in the
years since-by no means a unique story-the team's
philosophy has remained the same: start from first
principles, and let the why determine the what.
Our chassis department is the best reflection of this
mentality. Recent years have seen a great number of
successful teams adopt composite monocoque chassis
designs over traditional steel space frames. The trend
makes it easy for casual observers and junior members

8 April 2019

to mistake these differing concepts for differing levels of technology.
It's easy to forgive them; the sleek-looking monocoques of top Formula
SAE cars resemble those of today's fastest professional open-wheelers.
The common misconception is that these sophisticated monocoques
always reign supreme over their more conventional counterparts. The
truth is more nuanced, and plays an important role in our team's history.
UTFR may be one of the few teams in the Formula SAE/Student
paddock to use a hybrid chassis design, but it's one of even fewer teams
that have come "full circle" on chassis concepts. Looking into the team's
illustrious past reveals a diverse history-from space frames, to hybrids,
to monocoques-that have paved the way for our current philosophy.
The first iteration of UTFR's hybrid chassis concept was developed
in 2002, the team's third competition season. This innovative approach
replaced two of the rules-mandated side impact structure tubes with
composite side panels, though the cockpit still featured a top tube on
each flank. By replacing these heavy tubes with a sandwich panel of
carbon fibre laid up over a nomex honeycomb core, the 2002 chassis
saved 10 lb over its predecessor. Despite these advantages, the concept
retained most of the manufacturing simplicity of a steel space frame.
"At the time, there was nothing like what we had done. We got some
good comments from design judges," said Matthew Ferraro, 2002
Chassis Lead / 2003 Technical Director. "Carroll Smith [a prominent race
engineer known well for his Tune to Win series of books] had a soft spot
for us because he knew what kind of resources we had. He knew we had
to fight with our faculty just to survive."
The novelty of the original concept remained unchanged in
subsequent years. As a result of the in-plane shear strength of the
composite side panels, the midsection of the chassis was exceptionally
stiff in torsion, ensuring that minute suspension adjustments were not
lost to compliance. This was an important tuning advantage when UTFR
was one of the few teams that had access to accurate tyre testing data,
before the advent of the FSAE Tyre Testing Consortium. This knowledge
was important to developing the dynamics of the early 2000s cars, and
an effective chassis was a critical platform to build upon.

MOMENTUM



Momentum - April 2019

Table of Contents for the Digital Edition of Momentum - April 2019

Momentum - April 2019
Contents
A better MOMENTUM
Briefs
Reliability overhaul: a lesson in resilience
Turbulence on the track
Full circle
Lap simulation tool shows the way
Baja SAE technical inspection
VW’s MEB platform: a modularity enabler
The F-22 Raptor gets its first metallic 3D-printed part
SAE 101: WCX 2019
Moon shot as metaphor for autonomous vehicle technology
DOSSIER: Greg Sawvelle
Momentum - April 2019 - Momentum - April 2019
Momentum - April 2019 - Cover2
Momentum - April 2019 - Contents
Momentum - April 2019 - A better MOMENTUM
Momentum - April 2019 - Briefs
Momentum - April 2019 - Reliability overhaul: a lesson in resilience
Momentum - April 2019 - 5
Momentum - April 2019 - Turbulence on the track
Momentum - April 2019 - 7
Momentum - April 2019 - Full circle
Momentum - April 2019 - 9
Momentum - April 2019 - Lap simulation tool shows the way
Momentum - April 2019 - 11
Momentum - April 2019 - Baja SAE technical inspection
Momentum - April 2019 - VW’s MEB platform: a modularity enabler
Momentum - April 2019 - The F-22 Raptor gets its first metallic 3D-printed part
Momentum - April 2019 - SAE 101: WCX 2019
Momentum - April 2019 - Moon shot as metaphor for autonomous vehicle technology
Momentum - April 2019 - 17
Momentum - April 2019 - DOSSIER: Greg Sawvelle
Momentum - April 2019 - 19
Momentum - April 2019 - 20
Momentum - April 2019 - Cover3
Momentum - April 2019 - Cover4
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