Matador Motorsports, FSAE

The aerodynamic system's purpose is to produce downforce to increase tire grip during low speed cornering at high yaw rates. The scope of the 2023-2024 aerodynamic subteam is to design a lightweight and high-performing aero package. 

My role on the team involved overseeing the development of the aerodynamic package including performing high-level simulation, front wing design revisement, undertray design, sidepod design, and simplified car model design. As the lead CFD analyst, my responsibilities included repairing CAD models, setting up and running 3D CFD models, and post-processing results using Ansys and Excel to document vehicle behavior.

Designed the simplified car model which features bodywork, tires, suspension, driver, firewall and rear chassis. The model has integrated adjustable ride height, track width, wheel diameter, and adjustable steering angle with Ackerman. 

The simplified model development marks a significant milestone in aerodynamic analysis as it allows for a deeper analysis on suspension, tire and frame interactions with the vehicle in order to develop a refined aerodynamic package.

Throughout the development process, proper documentation was maintained to pass onto the upcoming years for seamless integration and future development.

My contribution to the front wing design involved exploring different airfoil profiles, modifying slot gap and overlap, and fine-tuning chord lengths and angles of attack. The final design resulted in ease of manufacturing and increased performance to the overall package.

The revised design featured a shortened 12 in. NACA0008 mainplate profile and a refined multi-element flap setup resulting in a 70% performance gain. 

During manufacturing phase, I designed the front wing fixture and performed carbon fiber layups to meet our manufacturing deadlines.

Following CDR, I volunteered for undertray design to solve performance and model issues within the assembly. With limited time, I researched ground effect theory, designed and simulated several iterations, and full car sensitivity studies to improve the undertray design resulting in a 126% performance gain. 

This marks a significant milestone for undertray design as a new design and part had not been made since 2017, and analysis conclusions were documented. 

During manufacturing phase, I contributed to the foam mold development, and performed carbon fiber layups to complete the undertray within deadline.

My contribution to rear wing design involved integrating rear wing pivot points to identify angle of attacks for passive DRS configuration. Through simulation, I defined optimal angles of attack to minimize drag for linear acceleration event.

Through CFD simulations, I documented new findings for future optimization related to mainhoop interaction with upper flaps resulting in detached airflow. 

During manufacturing phase, I assembled the rear wing including tapping endplate holes, trimming airfoils, and increasing truss support rigidity.

Designed the sidepod which featured a converging-diverging configuration to create a pressure differential vacuum. The optimized curved geometry resulted in reduced drag and minimized recirculation regions to improve cooling.

 The design had several complex constraints including the bodywork, frame, suspension, diffuser, and the cooling assembly.

The design features an improved geometry based on airflow interactions between front wing, tires and suspension with the inlet. The developmess process was documented for continued design optimization in the future.

Designed the brake cover reservoir within hours to resolve accessibility issues with brake reservoir fillers mounted on chassis. This design shares bolts with access panel and is easily removed for brake serviceability.

The female mold design was also designed using the same model to manufacture a medium density foam mold of this part quickly.

During manufacturing, I prepared the mold by sanding and applying sealer, and performed the carbon fiber wet layup with vacuum bagging to produce the part.