2. Introduction
About Formula SAE (FSAE)
In 1981, the Society of Automotive Engineers (SAE) in the USA began the "Formula SAE"
competition, in which around 140 student teams from all over the world compete every year.
Since 1998, SAE and IMechE (Institution of Mechanical Engineers) in England have been holding
the annual "Formula Student" competition, normally composed of around 70 international teams.
In 2006 Australia held the sixth "Formula SAE Australasia" with about 30 such teams. Now there
are teams of young engineers in Italy, Japan and Brazil competing with each other. The
competitions are conducted under nearly all the same rules and regulations, allowing the teams
to participate in several different competitions with little or no modifications to their work.
Team Profile
History
Alexandria University Motorsports team (AUM) is comprised of students from the faculty of
engineering, Alexandria University. It was first founded by a group of mechanical engineering
students in 2009. In 2010 AUM team has represented Alexandria University in the Formula
student Germany competition with the first car to be fully designed and manufactured by the
available resources. This encourages new students to sustain the project of building a prototype
race car and represent the University again in 2012 and 2013. AUM was the only team
representing Egypt in the FSG competition in the three appearances.
3. (Team 2013)
Competitions of 2016
-AUM team participation is confirmed in formula student Italy in the period of (22-25) July
Formula SAE Italy
Conceived in 1981 by SAE International (Society of Automotive Engineers) of the US, Formula SAE
spread quickly to the UK, Australia and Brazil thanks to its success and popularity amongst
engineering students in general.
Since signing a long-term agreement with SAE in 2005, ATA now organizes the Italian event in the
FormulaSAE circuit.
Formula SAE purpose is to encourage students and young graduates to design, realize and test a
single-seated racing car. They will be in charge of the project from the design to the marketing
stages. It provides each team involved the opportunity to face a real-life professional situation,
working in a team context with time deadlines and making both business and managerial
decisions in the process of tackling automotive engineering matters.
They will compete through both stationary tests and on-track trials and gain potentially useful
"work" experience.
Formula SAE Italy offers two level of involvement: Class 1 for teams intending to participate a
complete, fully-functional vehicle, Class 3 for those presenting a vehicle design.
During the event teams will be assessed by a panel of experts from the world of motorsport and
the automotive industry.
4. Formula SAE Italy will be held every July in accordance with the SAE calendar of international
student competitions.
Team Management
The team is participating in 2016 competitions with a new structure. A new way of managing the
team was developed by setting a hierarchy and job description to organize different roles. There is
a rules and regulations set by all the members to govern the code of conduct and to assure the
overall efficiency of the work done.
Also there is a strict timeline which the team follows. The timeline is divided into four phases;
research, design, manufacturing and testing.
A specific action plan was set for each technical team. The team is divided in to two directories
which are the supporting directory and the technical directory, all the team members are
participating in the technical directory and divided on 6 sub-teams and part of them is responsible
of marketing and fundraising the project under the supporting directory.
Team's hierarchy
5. Technical approach
-our goal is to build a race car with the highest power to weight ratio, stable through the corners
and extremely using innovative and bold ideas.
We are divided into 6 teams
1- Power team
-The engine’s team plan is to adopt the following ideas:
a- Cam shaft and manifold fine tuning gaining extra 20 HP more than last year’s car.
The use of turbochargers for high boosts pressure and higher mechanical efficiency
as high as 33%.
b- Integrated Rankin cycle for exhaust waste energy recirculation pushing the
mechanical efficiency figures up to around 35%
c- A/f ratio fine tuning using a tunable control module allows the car to have a
smother power curve with the same fuel consumption.
- Electrical team:
-The electrical team plan is to adopt the following ideas:
a- Designing and manufacturing a detailed harness according the SAE rules.
b- Designing and building traction control and torque vectoring modules.
c- Designing and building data acquisition module for advanced testing and tuning
2- Vehicle dynamics, suspension, Steering and control.
-The suspension and steering team plan is to adopt the following ideas:
a- Design a neutral steering car with high lateral acceleration using vehicle dynamics
fundamentals.
b- Using brake dynamic stability management for the ultimate vehicle control using
electronic aid helping the car to be more stable through corners thus much faster.
c- Torque vectoring, which is another way of using electronic aid to make the car faster
through corners by directing the vehicles torque to a specific wheel, increasing the
yawing moment of the vehicle for the same steering input.
3- Brakes team.
-The brakes team plan is to adopt the following ideas:
a- designing a race car braking system using tire and vehicle basic data for the optimum
braking bias and pressure.
b- Integrating traction control and torque vectoring using a parallel hydraulic circuit with an
electric pump and two accumulators.
6. 4- Chassis, Cockpit and ergonomics team
-The chassis team plan is to adopt the following ideas:
a- The use of lightweight materials and advanced manufacturing techniques to achieve the
lightest and strongest chassis.
b- Using advanced techniques to achieve the lowest cg height possible.
-The Cockpit and ergonomics team plan is to adopt the following ideas:
a- Design a safe and comfortable environment for the driver with a clear visibility.
b- Design a steering wheel with digital display and data logging.
c- Design paddle shifters and clutch paddles.
Aspirations
AUM team, just like any other racing team has the ultimate goal of achieving a remarkable
position and proving our team’s potentials. With this main objective in mind, our team narrows its
focus to a group of supporting goals which serve as guidelines for the team’s functioning and
development. Our primary objectives are as follows:
Student Development – FSAE competition enables students to gain hands-on experience by
enhancing their management, leadership and design skills.
Interdisciplinary Teamwork –AUM team brings together students from various departments and
academic years. Our team recognizes the benefits of working as a cross-functional team
Filling the Gaps – As well as providing a two-way relationship between students and
alumni/industry professionals, we extend our network to promote student’s engagement in
practical work.
Technical development - Evaluation of the prototype race car for its potential as a production
item which may appeal to the Egyptian and international markets.
8. Note that About 70 % of the manufacturing has been achieved
Budget
The private sector has a vital role in putting the designs into reality, without the support, our
team would not be able to manufacture the car and compete in FSAEItaly 2016 competition. Our
team must seek the support that can meet our growing needs. In the past, sponsors have chosen
to support us through:
Cash funding
Car components
Software Licenses
Manufacturing materials and Equipment
Design & Fabrication Services
Alongside what we have achieved in the current car that is being manufactured, the following table
shows the current budget of needed items.
9. Current budget
NO. Item Price in EGP Quantity Total in EGP
1 Tool box with torque wrench 2500 1 2500
2 TIG welding machine (200 A ) with variable
ampere & Voltage control
9000 1 9000
3 Argon cylinder 900 4 3600
Tires (wet) 1450 4 5800
4 cubic meters of Foam(Body) 900 3 2700
5 Fiber glass (Body) - - 4000
6 Manufacturing of body 6000 1 6000
7 Aluminum blocks - - 11000
8 CNC Machining for steering, pedal box and half
shaft & more
- 1 11000
9 Components for electronic and braking system - 1 21000
10 Vehicle shipping (air) - 1 90000
11 Travel tickets 4000 15 60000
12 Accommodation 3800 15 57000
13 Competition fees (registration & camping) 15000 2 30000
10. Sponsorship Opportunities
Formula student is a great opportunity for developing future engineers and preparing them for
professional careers. From the social responsibility aspect, sponsoring will help students to
combine between real applications and what they learn academically. It's an opportunity to
creating good leaders with project management and interpersonal skills. Private sectors'
engagement is a vital reason to achieve all these benefits.
The sponsor will gain access to the surrounding community of thousands of students, Engineers
and present governmental institutions and civil society entities. The sponsor will be promoted in
our marketing plan by appearance in TV, newspapers, radio and social media. Corporate's logo
appears on publicity printings and the car when participating in regional conventions, events and
internationally in the competition itself.
Packages:
Official sponsor (from EGP 100,000)
1. Car available in company’s events when requested by sponsor anytime
2. Main theme of the car will be designed according to sponsor’s logo.
3. Biggest size Logo appears on:
Main parts on the body of the car.
Team's apparel (t-shirt, hoody, etc.)
Printings (posters, brochures, etc.)
All social media content (photos, videos, etc.)
4. Sponsor's description to be promoted periodically on social media and team's website
with a direct link to the website of the sponsor.
5. Companies name will be stated as main (premium) sponsor of the team in media means
and newspapers.
Golden sponsor (from EGP 70,000)
1. Medium size logo appears on:
The body of the car.
Team's apparel (t-shirt, hoody, etc.)
Printings (posters, brochures, etc.)
All social media content (photos, videos, etc.)
2. Sponsor’s description to be promoted periodically on social media and team's website
with a direct link to the website of the sponsor.
3. Companies name will be stated as one of the sponsors of the team in media means and
newspapers.
11. Silver sponsor (from EGP 40,000)
1. Small size logo appears on:
The body of the car.
Team's apparel (t-shirt, hoody, etc.)
Printings (posters, brochures, etc.)
All social media content (photos, videos, etc.)
2. Sponsor’s description to be promoted periodically on social media and team's website
with a direct link to the website of the sponsor.
3. Companies name will be stated as one of the sponsors of the team in media means and
newspapers.
Contributor
1. Company’s logo only appears on printings, social media and website stated as
contributor.
2. The logo and name will be presented in the contributors’ area on the body.
12. AUMotorsports Marketing Events
Bibliotheca Alexandria event
The project aimed to make students (12-16) years old aware of the basic scientific
principles behind car operation, so they can be aware of the importance of the academic
studies taught at schools.
It also sparked their interest in design and manufacturing of simple applications of
different scientific projects.
Moreover, it developed their skills of creative thinking, problem solving,
communication, teamwork and leadership.
The project was five days long; each day participants attended a session and a workshop
to illustrate the academic content in practical.
The project took place at Bibliotheca Alexandrina from the First of February till the Fifth of
February and the closing ceremony was held on the nineteenth of February.
13. Our latest Formula Car of 2013 was exposed at the plaza starting from 27th
of January till
5th
of February. Thousands of people saw the car with the sponsors' logos on its body,
they interacted with our team representatives and they were welcomed to take photos
The closing ceremony had the theme of that a generation achieved a design and
manufacture an Egyptian car completely and the other generation which was taught and
inspired from their early age
The promo video which illustrates the idea is on this link:
https://www.youtube.com/watch?v=UkS6mh3mKAE
The team announced and presented the complete design of our new car of 2015 for the
first time, the car which will participate in Formula Student Italy (11-14) septamber and
illustrated its specifications and explained how each component works.
At the end of the ceremony the best five juniors were announced to join our team in the
manufacturing phase of 2015 car. The participants were awarded their participation
certificates by the project manager, the team's faculty advisor, dean of faculty of
Engineering, director OF engineering syndicate in Alexandria and director of military
scientific research and quality assurance department in Egyptian naval forces. Corporates
representatives were invited and attended the closing event too.
14. Faculty of engineering event
(How I met your car)
Although the team manufactured 3 formula cars in 2010, 2012 and 2013, but the
around 15000 student never saw the car in the faculty or interacted with the
previous team. The team started a campaign online to announce our first
appearance in the faculty after publishing a promo video, the link:
https://www.facebook.com/video.php?v=845076132202470&permPage=1
The old car of 2013 was exposed for the first time to audiences on 25 December.
A photo session were held and team's printings were distributed brochures and
business cards with contacts and QR code of the Facebook page.
15. Future events
1) There is a big event that will be organized with bibliotheca Alexandria in
summer it's confirmed and we are still in planning. The new car will be exposed in
the plaza. A big banner with the current sponsors will be exposed
2) The team is working on appearing in clubs, malls of Alexandria or any place
were big number of people gather. This plan is for summer too when the
manufacturing of the car is over. Negotiations are ongoing.
16. AUMotorsports in Egyptian Media and Newspaper
-ل الرسمية الصفحة mbc مصر(9)متابع مليون
-""الوطن جريدة
23. AUMotorsports car 2016
The past team attempts showed that a simple and rugged design is faster and cheaper to
produce and gives a higher reliability due to the extensive use of steel and aluminum
materials. More sophisticated materials would save more weight, but we’re focusing on
having a higher power to weight ratio of 0.29 hp/kg, a high and flat torque curve of 50 N.M
over 6000 rpm to 9000 rpm region, and a high FDR of 3.25. Electro-pneumatic shifting is
going to be used for less acceleration times. This concept gives a high performance on
tight Autocross circuits. The ECU will be a Mega Squirt III with integrated data logger for
engine parameters, and a supporting Data Acquision System will be used to monitor and
log the vehicle dynamics parameters.
Regional manufacturing facilities were scanned and analyzed based on the past team
attempts. The team will depend only on tested manufacturing facilities, within a circle of
just 50 km radius, hence there’s no need for overseas manufacturers so there’s no extra
time needed for the engineers to familiarize with very advanced manufacturing facilities
and taking time or effort to learn them. So at the expense of a little heavier vehicle, we
have faster general production schedule and more R&D flexibility where the team can test
many minor concepts on the same vehicle fast.
We are also trying a totally different manufacturing method this year by purchasing the
basic machines we need for the production. For example, we’re going to start with a
Lathe, Mill, and a Welding machine where about 80% of the production work on the car is
done by those machines the plan is to overcome problems caused in the past by
depending on outsourced manufacturing facilities.
24. AUM 2015 car design
This year the team planned the project period into 4 phases
First phase was educational and research which took 2 months. The design phase which
was 6 months of hard work was finished on 19 February 2015 and announced for the first
time. Also the beginning of manufacturing phase was announced. The last phase is
testing before participating in the competition
Chassis:
Space frame, Heat treated AISI 4130 tubes, TIG welded.
Suspension and steering:
Double unequal wishbone, Pull rod actuated, Custom spring, Elka Suspension dampers.
And custom rack & pinion, custom steering wheel.
25.
26. Brakes:
Student designed rotor, Wilwood PS1 and Dynalite Single Calipers, AP Racing Master
Cylinders
Wheels and tires:
13” Braid Sturace rim, AVON A45 Tires.
27. Electronics:
Pneumatic shifting, MegaSquirt III ECU, LabJack Data Acquision System
Engine:
Honda CBR600RR 2008, 4 cylinder, 70 bhp, Student modified lubrication, intake, exhaust
and fuel systems.
30. Contact information
We hope to accomplish our mission in Formula SAE with your firm support. If you like to have
further information about the team or sponsor benefits, please feel free to contact us via phone
or e-mail. We would be highly privileged to discuss it further with you.
Dr. Yehia Eldrainy
Professor & Faculty Advisor
Associate Professor & Technical Supervisor
Dept. Of Mechanical Engineering, Faculty of Engineering, Alexandria University
Mobile: +2 01015393646
Email: yeldrainy@alexu.edu.eg
Ahmed Emad
Project Manager
Mechanical Engineering student
Faculty of Engineering, Alexandria University
Mobile: +2 01009045987
Email: ahmed.emad1992@gmail.com
Omar Hesham
Public Relations
Mechanical Engineering student
Faculty of Engineering, Alexandria University
Mobile: +2 01144147900
Email: eng.omar.hisham@gmail.com
