PROJECT: MODIFIED

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Middleburgh High School
2004 UHS PRINCIPLES OF ENGINEERING
Thursday 330
Friday 900
PROJECT MODIFIED
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UHS Principles of Engineering is a 3 credit
University course offered at Middleburgh High
School in cooperation with SUNY Cobleskill. This
40-week course introduces the students to
engineering through the use of case studies. The
students are given 5 case studies throughout the
year, each having different requirements, and
each increasing in skill level.
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Technology _at_ MCS
PRINCIPLES OF ENGINEERING                      
                                                  
                                                  
                                                  
                                                  
                                        
For their final project, students designed,
engineered, and constructed, 5 quarter-scale
MODIFIED RACE CARS.
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The students were grouped in teams of three, and
were given limited materials for the construction
of their cars. The cars are powered by model
airplane engines and are radio controlled. Each
capable of reaching speeds over 40 MPH.
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The students each had to raise 300 in sponsor
money in order to complete the project. Each car
cost approximately 1100 to build. Many materials
were also donated by local companies.
Special thanks to all of our Sponsors MIDTEL.NET,
Fonda Speedway, Randy Snyder Engineering, Racing
With Heart, Bob Elliot Gears , Kintz Plastics,
Bishop Racing Products, Mid-Valley Auto Parts,
Middleburgh Rotary, Integrated Liner
Technologies, Century 21, Advantage Mortgage, JJ
Racing, Shaul Roofing, Becker Excavating, Jan E.
Parkes, Barber's Farm, Roehrs Design, Hubbie's
Restaurant Pizzeria, Ryan's Auto,
Laraway's,INC., Good Earth, Rudolph Donald
Snyder, Den's Tire, Borst Oil Tire, Middleburgh
Hardware, MM Masonary, NAPA of Cobleskill,
Roosevelt's Towing, Iron Horse Welding,
Renesselaer Iron Steel, Itatique, Holland
Hucksburg, , Kenneth General Contracting, Valley
Pharmacy, Ski Windham
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The students learned how to use a variety of
fabrication processes in the lab such as welding,
machining, taping, bending, shearing, sawing.
These photos show the use of the metal lathe for
the fabrication of our hubs and tie rod ends.
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We also integrated the abilities of our CNC
Machine, and CAD software to design, develop, and
machine parts for the cars.
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This project was designed to enhance the students
knowledge in the following areas

• ? Facilitate brainstorming activities.
• ? Create working CAD drawings and 3-D Models.
• ? Identify different types of metal plastic
  fabrication equipment.
• ? Fabricate Lexan frames using machining
  equipment.
• ? Operate a CNC Milling Machine and Lathe to
  fabricate parts.
• ? Apply auto body paints, primers, and graphics.
• ? Create web sites for posting team information
  and photos.
• ? Describe and illustrate the physics associated
  with auto racing.
• ? Identify vocabulary used for describing
  mechanical systems.
• ? Build and install radio-controlled devices.

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Each race team was responsible to complete the
following
objectives

• ? Appoint a Crew Chief and team members.
• ? Create team Name, Logo, Letterhead,
  Website, Bus. Cards.
• ? Arrange for team sponsorship.
• ? Develop a design, which follows the
  project constraints.
• ? Put those ideas on paper, in AutoCAD, and
  in SolidWorks.
• ? Gather materials and supplies.
• ? Develop car setup and driving procedures.
• ? Post accomplishments and credit sponsors
  on their website.
• ? Build car based on their Virtual
  Prototype.
• ? Complete 4 written design reports, and a
  Project Portfolio.
• ? Create a CD of drawings and photos.

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This project satisfies NYS Standards through the
following activities

• 5.1 Engineering Design
• ? Identify, locate, and use a wide range of
  resources, including the internet, business
  experts, vendors, and sponsors.
• ? Generate creative solution ideas in their team.
• ? Optimize their ideas, and refine their
  solutions.
• ? Predict possible outcomes and flaws in their
  design.
• ? Develop work schedules and plans, which
  optimize materials.
• ? Incorporate modifications while working to a
  high degree of quality.
• ? Take on responsibilities which will optimize
  their team, based on their expertise.

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5.2 Tools Resources ? Select appropriate tools
and equipment, and use them correctly to process
materials and information. ? Describe and use
computer based methods to control system
processes. ? Explain tradeoffs made in order to
reduce cost and save time.

• 5.3 Computer Technology
• ? Use CAD software to model realistic solutions
  to design problems.
• ? Use spreadsheets to document expenses.
• ? Use word-processing software for creating
  design reports and sponsor correspondence.
• ? Use web creation software to develop
  professional web sites.

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Each student has to take on specific
responsibilities for the project.
Crew Chief Responsible for overseeing all group
activities, and members. The crew chief will
also hold one other job title as well. All
correspondence must have the Crew Chiefs
approval and signature. The Crew Chief is also
responsible for arranging vehicle sponsorship,
documenting transactions public relations. Body
Specialist Responsible for overseeing the
construction of the body to specification. Will
also be responsible for painting and graphics of
sponsor logos. Frame / Engine Specialist -
Responsible for overseeing the design and
building of the frame. Also responsible for the
operation and mounting of the engine to
specification. Draftsman - Responsible for
overseeing the construction of the vehicle in
Solidworks and AutoCAD prior to construction.
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The race teams are each given a project
outline which details their responsibilities and
also lists the constraints of the vehicle.
Specifications The following
specifications must be followed a. Overall
length min 45 max 48 b. Wheelbase
min 25 max 26 c. Ground clearance - min
1 max 2 d. Width (outsides of tires) -
min 18 max 19 e. Maximum Height will not
exceed 16
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The Design Process

• AutoCAD Drawings

• Solidworks Drawings

• Class Prototype

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AutoCAD Drawings
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AutoCAD Drawings
Also used for cutting the graphics.
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Solidworks Drawings
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Solidworks Drawings
Front Hub
Rear Hub
Hub Screw
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Solidworks Drawings
Screw
Shock
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Solidworks Drawings
Wheel
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Gear
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Solidworks Drawings
Frame
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Solidworks Drawings
Front Assembly
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Solidworks Drawings
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The Building Process

• Prototype

• Jigs Fixtures

• Research Dev.

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Front Assembly
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Engine Frame
G2D70 Zenoah
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Assembled Prototype
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Clear Lexan Body
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CAD / CAM
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Metal Preparation
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Sanding
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Jigs Fixtures
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Welding
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Pipe Cutting Bending
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Machining
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Sandblasting
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Grinding
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Paint Assembly
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Polishing
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Race Teams
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Race Teams
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Middleburgh High School
2004 UHS PRINCIPLES OF ENGINEERING
Thursday 330
Friday 900
PROJECT MODIFIED