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DESIGN AND OPTIMZATION OF A FORMULA SAE COOLING SYSTEM

Neal Persaud

A thesis submitted in partial fulfillment of the requirements for the degree of BACHELOR OF APPLIED SCIENCE

Supervisor Professor M. Bussmann. Department of Mechanical and Industrial Engineering University Of Toronto March 2007

ABSTRACT
This thesis documents the testing, design and analysis performed to determine the optimal design for the 2007 cooling system for the University of Toronto Formula SAE race car. The main focus of this project is the physical testing and analysis of the data collected. The cooling system design has been refined as a result of the testing carried out in this project. The test data has been analyzed to identify heat rejection requirements, optimal engine operating temperature, and other important design parameters. It has been found that the cooling system used in the race car must reject 9500 Watts of heat energy, and should aim to maintain an operating temperature of 85°C. The 2007 cooling system promises to be successful and an improvement over last years system. The new system is 10% lighter than the system it replaces, contributing to the overall improvement of vehicle performance of the 2007 University of Toronto FSAE race car.

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Acknowledgements
The author wishes to acknowledge the following people for their much appreciated help and support during the course of this thesis: o Professor M. Bussmann for graciously agreeing to supervise my thesis and the for his role as the University of Toronto Formula SAE Faculty Advisor. o Long Dana Manufacturing for providing radiators and continued support of the University of Toronto FSAE team. In particular I would like to thank Martine Banville, Stephanie Sesitito, Nick Kalman, and David Bruce from Long Dana manufacturing for assisting in the radiator procurement as well as providing proprietary testing data that proved to be invaluable.

o Jeremy Koudelka and Jerry Zielinski for assisting me during my first year as cooling system design leader

o Nilufar Damji and James Correia for their help in conducting performing cooling tests and test component manufacture

o Huang Iu and Saquib Siddiqui for their help in developing, troubleshooting, maintaining, and operating the engine dyno

o Andrew Wong for his excellent photography skills o To past and present members of the Formula SAE team who have helped me to develop into a competent young engineer. The knowledge and practical experience gained by being a part of this team has profoundly affected my life and will continue to do so for many years to come.

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Table of Contents
ABSTRACT .. ……………………………………………………I ACKNOWLEDGEMENT .. ……………………………………II TABLE OF CONTENTS…...…………………………………III GLOSSARY ................................................................................... V 1 INTRODUCTION……………………………………………. 1 1.1 Purpose.................................................................................................... 1 1.2 Formula SAE.......................................................................................... 1 1.2.1 Background........................................................................................ 1 1.2.2 Formula SAE Rules .......................................................................... 3 1.3 Literature Review.................................................................................. 3 1.4 Motivation............................................................................................... 4 1.4.1 History .............................................................................................. 4

2 OBJECTIVES .............................................................................. 6

2.1 Design Objectives................................................................................... 6 2.1.1 Design Constraints............................................................................ 7 2.2 Design Requirements...
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