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WILLIAM KERLEY

Mechanical Engineering Portfolio

Winter 2011


W

ith current trends in automotive manufacturing forging a new environmentally conscious product, I believe it is up to the motorsports industry to prove and develop new and

creative

technology.

This

new

era

of

automotive

identity and the challenge to develop and implement new ideas in a competitive environment is what defines my career aspirations.

I have de-

signed, developed, proved, and innovated over the past five years of my motorsports engineering involvement. I am unafraid to kick the trend, try new ideas, and learn from my mistakes.

Through my experience, I have

the drive, determination and creativity to help contribute efficiently to a professional motorsports team.


2005-2010

McGill Racing Team

SUMMARY 2008-2010, MRT-11 and MRT-12 Team Captain •

Organized and managed over 30 graduate and undergraduate engineering students in a year-long project to develop a prototype single-seat Formula SAE race car. Facilitated the logistics of design, manufacturing and competing in a racing team through the help of faculty, industry leaders around Montreal, sponsors, and fellow design teams. Tested the prototype in competition, validated through data-acquisition

2006-2010, MRT-9 to MRT-12 Sponsorship Manager •

Developed new partnerships with corporations, companies and industry leaders to fund the McGill Racing Team Improved the presence of the McGill Racing Team throughout McGill University and Montreal through a unique marketing and sponsorship approach Total of over $60,000 raised over three seasons (full budgets)

2005-2007, MRT-8 and MRT-9 Body Design Team Leader •

Designed and manufactured five-piece composite bodywork through CAD surfacing and traditional methods.

ACCOMPLISHMENTS 1st Place, Ford Motor Company Fuel Efficiency Award (2009) 14th Place Overall, FSAE EAST, Detroit (2009, out of 120 participants) Established a new team image over three years (2007-2010)

$60,000 of sponsorship over three seasons Improved team structure, knowledge transfer, and design methodology Gathered over


McGill Racing Team

MRT-12

2009-2010


2009-2010

McGill Racing Team

MRT-12 •

• •

Earliest completion date with more testing time for driver and vehicle development. Focussed on teaching new team members proper procedure and methodology to ensure knowledge transfer. Designed and developed a new powertrain package using three levels of theory and testing (gain of 25%). Performed cold-testing to validate intake and exhaust performance. Use of Carbon Fibre chassis components leading to the lightest vehicle the team had produced (180 kg). Further emphasis on sponsorship value, lean manufacturing, validation through data acquisition.

Improved team dynamics


2008-2009

McGill Racing Team

MRT-11

• • • • • • • •

14th Place Overall, FSAE East (out of 120 entrants) 1st Place, Ford Fuel Efficiency Award

New single-cylinder powertrain package Focus on simplified manufacturing processes Carbon Fibre re-enforced chassis Streamlined development to improve testing Strengthened sponsorship loyalty through rewards , visits and incentives Further improvement of team organization, “brand” image, and campus recognition


2007-2008

McGill Racing Team

MRT-10 • • •

Improved team sponsorship through refined structure and goals New team logo, mentality, and hierarchy Emphasis on data-acquisition de-

velopment •

Organized

industrial partnership and research program to machine

and analyze material properties of

Aluminum Discs. •

Composite

Brake

Plagued by inexperience, lack of knowledge transfer, lack of established design guidelines, aging parts inventory.


2006-2007

McGill Racing Team

MRT-9

• •

Five-piece composite body work Sponsorship and marketing work for competition


2005-2006

McGill Racing Team

MRT-8

• • • •

Three-piece composite bodywork Carbon fibre composite panelling and floor Pro/Engineer CAD surfacing Master, Mould, Part process


2010-2011

VdeV Endurance Prototype

VEHICLE DYNAMICS SOFTWARE DEVELOPMENT

AERODYNAMIC DEVELOPMENT (CFD) Design and simulation of a Le Mans-style prototype air intake • Prepared surface models of vehicle and air intake through CATIA V5 • Use of CFD and post-processing visualization software

Developing a simple, easy-to-use interface as an effective tool to begin vehicle design and development through VB.NET framework. • Stability/Control investigation through Yaw Moment Diagrams • User-defined tire model coefficients and characteristic curves • Ability to read and analyze tire testing data • Suspension-load calculation • 2D kinematics visualization


2009-2010

McGill University

COLD-TESTING RIG

PROBLEM: •

•

Engine development involves countless hours of dynamometer time, which burns and consumes fuel in large quantities. The McGill Racing Team (2009) was left without any experienced students in powertrain, and needed a tool to quickly and efficiently teach new students as well as test and prove new components.

SOLUTION: Integrated three levels of testing and validation to improve education and to safely test new sensitive engine components (plumbing, intake and exhaust). 1) 1D Engine Simulation: Initial theory exercises 2) Cold Testing Rig: Externally drive engine through a DC motor. Through simulated operating conditions , the performance of the intake, exhaust (through mass air flow measurement), and plumbing could be measured and correlated. 3) Traditional Dynamometer Testing: For fuel and spark correction maps.

RESULTS: 25% MORE power over previous years 50% LESS fuel consumed during development SAFER testing procedures Increased educational value of FSAE project


McGill Racing Team

SPONSORSHIP

Re-evaluated sponsorship structure with realistic goals and benefits • Greater awareness, wider recognition (auto shows, F1 grand prix display, school exhibits) Re-focused sponsorships efforts on educational worth, local exposure and related industries • Over $60,000 raised in three seasons Re-energized team brand and enforced professionalism through improved uniforms, logos, colours. • Greater educational experience.

2007-2010


EDUCATION

Institut Superieur des Materiaux et Mechaniques Advances—Le Mans, FRANCE. Conception Automobile Advancee (Advanced Automotive Design), 2010-2011 McGill University—Montreal, QC, CANADA B.Eng, Mechanical Engineering (Distinction), 2010. CGPA: 3.61/4.0

TECHNICAL SKILLS

CAD Design – CATIA V5, Pro/ENGINEER, SolidWorks CFD – STAR CCM+, EnSight/Enlighten (Post-Processing) Data-Acquisition – MOTEC, ISAAC, Pi, AiM Engine Management – MAP3000 Engine Simulation Software – Lotus Engine, Ricardo WAVE Suspension Kinematic Simulation – OptimumK Finite Element Analysis – ANSYS Workbench Machine Tools and Fabrication – Lathe, Mill, Welding (TIG) Graphic Design – Adobe Illustrator, Photoshop Technical Computing – VB.NET, Matlab (Simulink), VBA, Maple

TECHNICAL EXPERIENCE 2010-2011 ISMANS Competition, VdeV (FIA CN) Championship – Le Mans, France

Design Engineer, 2010-present - System integration and development of an FIA CN prototype racing car for participation in the 2011 VdeV championship - Perform iterative design on components using CFD and suspension kinematics software

2005 – 2010 McGill Racing Team, Formula SAE – McGill University, Montreal, QC

Team Captain, 2008 – 2010 - Organized and managed over 30 graduate and undergraduate engineering students in a year-long project to develop a prototype single-seat Formula SAE race car. - Facilitated the logistics of design, manufacturing and competing in a racing team through the help of faculty, industry leaders around Montreal, sponsors, and fellow design teams. - Tested the prototype in competition, validated through data-acquisition - Led team to its best result in history at FSAE Michigan 2009, finishing 14 overall - Won Ford Motor Company Fuel Economy Award as the most fuel efficient Formula SAE Vehicle, FSAE Michigan 2009. Mechanical Engineering Project – Cold Testing Rig, 2009 – 2010 - Validated the use of cold testing through data-acquisition and computer simulation to improve the performance of intake and exhaust system Sponsorship and Finance Manager, 2007 – 2008 - Developed new partnerships with corporations, companies and industry leaders to fund the McGill Racing Team - Managed funds and compiled a comprehensive cost report - Improved the presence of the McGill Racing Team throughout McGill University and Montreal through a unique marketing and sponsorship approach Aluminum Composite Brake Discs, 2007 – 2008 - Manufactured aluminum composite brake discs through the implementation of diamond coated cutting tools. Body Team Leader, 2005 – 2007 - Led members in the design and manufacture of fiberglass body panels through three-stage plug/mold/part process. th



William Kerley Portfolio, Winter 2011