catia project (completed)

F1 master

Final Engineering Report

Engineering Project Mechanical

OENG1053

Mr Pattabhiraman Malavalli

Ehinomhen Oseghale s3434470

Masood Naziri s3433405

Atiqullah Ataei s3379403


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Contents Acknowledgements ..................................................................................... 2

Executive Summary .................................................................................... 2

Introduction (Background) ............................................................................ 2

Resource planning ...................................................................................... 3

Project Planning ........................................................................................ 4

Loading and Scheduling ................................................................................ 5

Risk Assessment ......................................................................................... 5

Concept design ......................................................................................... 7

Team formation ........................................................................................ 8

Design tools ............................................................................................ 12

Design Criteria ......................................................................................... 13

Communication Methods ............................................................................. 14

Product Design and Development ................................................................... 14

Process Design and Development ................................................................... 17

The Putting the design and development together requires a lot of work and skill, and the most

important tool is the machine/s used in finalizing the design. Below is the summary of the most

important machine, the MakerBot ...................................................................... 17

Product Validation .................................................................................... 20

Conclusion .............................................................................................. 25


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Acknowledgements

Firstly as a Group, we would very much like to thank our teacher Mr Pattabhiraman

Malavalli as well as RMIT University for guiding us throughout the 12week span of

our engineering project; we would also like to thank our teacher for always being

there to give us accurate and detailed feedback.

Executive Summary

The aim of this report was to experience a real industry engineering project and to

have acknowledgement of what the real industry will be like. After discussing with the

team on what will we be doing different and better to make the F1 car from the

previous knowledge’s that we have achieved over the three semesters, as a team we

came across with what will be our problem that we will be facing, it was the weight of

the car while maintaining our design that we agreed to make. While we were

designing the car on Catia we would check the weight after every part so that anything

that will make it overweight we would reconsider as a team and bring some changes

to the design. Concluding the report when making a design the weight and size should

be conformed and considered while making the design so later there is no big changes

are needed and saves time. It is recommended that the design restrictions and

guidelines are properly read and some research is done.

Introduction (Background)

This report presents the design of a Formula One car and also introducing the group of

3 which includes Ehinomhen Oseghale, Masood Naziri & Atiqullah Ataei and

displays system used during the initial and final construction within a 12 week span.

This design plan makes use of the MS document, while the design and development of

the car was done using CATIA and Solidworks programs. The length and weight

measurement were both within the criteria stated, which are 200mm and 70grams

respectively. In this design the overall objectives set in the criteria sheet were met. By

keeping track of the weight and length, the design is required to attain the best

possible speed and overall functionality. The design structure was carefully made; also

it was flushed and finely finished to give it the best possible output for an F1 car. The

mass and density is 80grams and 1240kg/m respectively. After completely designing

the F1 car, as a team we then proceeded to applying the recommended aerodynamic

test with the aid of solidworks program. This significantly added an extra star to the

design. In this report we clearly explained/expanded on all procedures and steps taken

in the creation of our astonishing Formula one car.


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Resource planning

In order for the group to finalize anything about the design elements of the F1 car,

first we must know what exact resources (people, equipment, materials) are needed

and also in what quantities to successfully perform the project activities.

REFLECTION

High 80% - 100%

Low 20% - 60%

Standard 70% - 100%


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Project Planning

In our project, as a group we came up with an idea of creating the most

advanced/comfortable F1 racing car model. There were several processes put into the

structure and development of the F1 car. The first task at hand was to create 1

individual f1 model car each. At the end of the fourth week, we had to make a

decision, which involved choosing only one out of the three models. In our opinion

this was the best one of them all. Below are the 3 models and a caption of what they

represent;

ATIQULLAH ATAEI DESIGN

MASOOD NAZIRI DESIGN

EHINOMHEN OSEGHALE DESIGN


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Loading and Scheduling

As this was a group project the work load had to be divided amongst the group

members. We all decided to do some work in all parts of the project to get the best

knowledge in the project whilst specialising in a specific part of the project. The

design of the f1 car was specialised by Masood and the report of the car was

specialised by Ehinomhen whilst the calculation and theory such as aerodynamics and

weight, size was monitored by Atiqullah. The scheduling of the project was set from

the first week of commencing the project and everyone in the group had their set work

and due date were all set. The group was in contact through social network and other

means of communication. If anything was wrong we would analyse it quickly there

were not a lot of millstones in the project as we had plenty of time to do the project.

The projects main goal was for us to get a real engineering project experience while

we have fun doing the project.

Risk Assessment

There are no great hazards involved in this project basic common sense practises

should be considered at all times. While making the design it can be really lengthy and

tiring so small breaks should be taken to rest the eyes and proper seating position

while sitting on the computer for the back and eyes to avoid any permanent injuries or

problems. During the actual 3d printing session the basic instructions for the 3d printer

should be followed.

Likelihood Consequence

Insignificant Minor Moderate Major Critical

Almost Certain Medium Medium High Extreme Extreme

Likely Low Medium High High Extreme

Possible Low Medium High High High

Unlikely Low Low Medium Medium High

Rare Low Low Low Low Medium


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Consequence Description of Consequence Likelihood Description of Likelihood

1. Insignificant No treatment required 1. Rare Will only occur in exceptional circumstances

2. Minor Minor injury requiring First Aid treatment (e.g. minor cuts, bruises, bumps)

2. Unlikely Not likely to occur within the foreseeable future, or within the project lifecycle

3. Moderate Injury requiring medical treatment or lost time

3. Possible May occur within the foreseeable future, or within the project lifecycle

4. Major Serious injury (injuries) requiring specialist medical treatment or hospitalisation

4. Likely Likely to occur within the foreseeable future, or within the project lifecycle

5. Critical Loss of life, permanent disability or multiple serious injuries

5. Almost Certain

Almost certain to occur within the foreseeable future or within the project lifecycle

Hierarchy of Control

Most effective

(High level)

Least effective

(Low level)

Elimination: remove the hazard completely from the workplace or activity

Substitution: replace a hazard with a less dangerous one (e.g. a less hazardous chemical)

Redesign: making a machine or work process safer (e.g. raise a bench to reduce bending)

Isolation: separate people from the hazard (e.g. safety barrier)

Administration: putting rules, signage or training in place to make a workplace safer

(e.g. induction training, highlighting trip hazards)

Personal Protective Equipment (PPE): Protective clothing and equipment (e.g. gloves, hats)

Assessed Risk Level Description of Risk Level Actions

Low If an incident were to occur, there would be

little likelihood that an injury would result.

Undertake the activity with the existing

controls in place.

Medium

If an incident were to occur, there would be

some chance that an injury requiring First Aid

would result.

Additional controls may be needed.

High

If an incident were to occur, it would be likely

that an injury requiring medical treatment

would result.

Controls will need to be in place before

the activity is undertaken.

Extreme

If an incident were to occur, it would be likely

that a permanent, debilitating injury or death

would result.

Consider alternatives to doing the

activity.

Significant control measures will need

to be implemented to ensure safety.


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Concept design

The first thing a quality design needs is a well prepared and furnished project plan.

With the aid of an MS document we carefully planned out a concept of any model car

of our choice and then we moved on to designing it on CATIA. Our F1 car model of

choice was based on an original formula one model, different ideas were drawn from

several original model. This skill of merging many different ideas together is what

makes our design different from every other F1 car out there today. As a group, we all

individually put in our separate concept design ideas towards the building of the car.

This is one of the many reasons why this F1 car is unique. During the construction of

the car, we kept in mind the required weight, length and dimensions required. The

next step on our agenda was to put the F1 car through an aerodynamic test using the

solidworks program. Aerodynamics in automotive is the study of the aerodynamics of

road vehicles. Its main goals are reducing drag and wind noise, minimizing noise

emission, and preventing undesired lift forces and other causes of aerodynamic

instability at high speeds. For some classes of racing vehicles, it may also be

important to produce down force to improve traction and thus cornering abilities. This

test was successfully completed for the model car. Clearly explained photos will be

attached later in this report.

1. Description of Hazards / Risks

2. Risk Level

1. Control Measures

Making a mistake in the design of the car which will be ineffective and waste of money.

High In order to control this risk great caution should be taken with the design and the limitations and design requirements should always be taken in consideration when designing.

Using electric equipment’s

Medium When using things associated with electricity always make sure that the surroundings is safe and checking for any open wires.

Making the design on time.

High Handing in the designs on time is very important as there is a one week printing session this should be controlled since the start of the project holding team meetings and following the project plan meeting the deadlines.


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Kinematics and Kinetics of the Model f1 car


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Team formation

As a team we all collectively contributed in these various aspects;

MEET THE TEAM

- Project Manager & Manufacturing Engineer

- Design, Graphic & Manufacturing Engineer

- Testing & Manufacturing Engineer


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Weight management

Above are the weight, density, area and volume. Notice how the density was updated

from 1000kg_m3 to 1240kg_m

3. This was done because it was clearly specified on the

criteria sheet. Also note the mass will subject to change after it has been 3D printed.

Mass after 3D printing is 70grams. This happened because the material used in the

CATIA program is Metal, which the output is in PLA plastic (Polylactic acid plastic)

Organisational factors and diagram

Without a doubt there were several organisational factors involved in our project.

There were both positive and negative factors right from the initial project planning up

to the project conclusion. The factors include;

- Demands related to tasks and roles

- Quantitative overload, qualitative overload and mental effort

- Insufficient work

- Role conflicts and ambiguity

- Individual participation in decision making

- Physical environment and working conditions

- Work/time schedules

- Work recognition

- Information/communication flow


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Impact of design methods and Regulations

On the first day of class we were told that we are going to model a F1 race car for our

project thru out the semester and we were provided brief project criteria sheet and

with regulation on how to have a successful design. We start researching for type of

models to design our Race Car, and start with 2D sketching and then CATIA. Thru

out modelling our design, we were doing very well at the start, but later the impact

that we face thru out our design methods and regulations, was that our model was

actually quite off the regulations requirements. The mass is a bit heavier that we

planned to design it but beside that the output was successful with regulations and

requirements.


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Discussion and strategic consideration

During the initial planning of the F1 model car, as a group we came up with several

ground-breaking industry quality ideas which are as follows;

- Stability

- Aerodynamics

- Chassis

- Cockpit

- Spoiler

- Sufficient engine space

- Wheel alignment etc.

From left to right Cockpit & Spoiler.

Design tools

CATIA V5R21

Solidworks version 2013/14

3D printer

Microsoft office

- Microsoft project

- Microsoft PowerPoint

- Microsoft word


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Design Criteria

Front/Rear aerofoil span min 40mm/max 60mm

Front and rear Aerofoil chord min 15mm/max 25mm

Front Aerofoil thickness min 1mm/max 12mm

Rear Aerofoil Thickness min 3mm/ max 12mm

Whole of the front Aerofoil when viewed from the side must be in front of the centre

line of the front axle

Whole of the rear Aerofoil when viewed from the side must be behind the centre line

of the rear axle

The bottom surface of the aerofoil must be higher than the highest point of the rear

wheel when measured normal to the track surface

Track width is 300 mm wide and 18.25 metre long. A 50 mm high side walls are built

for safety

CO2 cartridge chamber diameter is 19.1mm.

Centre of the cartridge chamber diameter given in the stock drawing, Refer Stock

drawing (measured from track surface to centre of the hole CO2 chamber)

Depth of the hole min 50mm/max 60mm

Wall thickness around the cartridge Min 3 mm

Clear space surrounding the CO2 cartridge below 3mm

Wheel dimensions

The group made the holes for the axels as 6.00mm the Makerbot machine drilled the

holes perfectly. The wheel length and width are 33mm & 15.20mm respectively.

Below are photos of the wheel;


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Communication Methods

Google docs

Email

File exchange

Product Design and Development

On the first day in the class I read the instructions of the project brief, then

created a group of 3 and sat in on meetings with my group members, then wrote up

the related paperwork. Together as a group we read up on the rules & regulations

given out.

Next on our agenda we officially started project planning on MS project

document, began brainstorming and generating relevant ideas as a group. Before

officially starting my design the team realised that we had to adequately represent

an F1 car with the design of our choice.

Individually we did a lot of research prior to starting this gave us the

opportunity to know our design very well, and then began the commencement of

the design. The next big step was commencing the car modelling and initial design

using CATIA.

Body Design for reliability and durability

The reliability and durability of the F1 car is significantly equivalent to several F1

models out there today. Everything about the model is tweaked and tooled for one

thing and one thing only speed. Formula One car can easily attain speeds of 200 mph

but during a race, the speeds are generally lower. For example during the 2006

Hungarian Grand Prix, the winner's average speed was 101.769 mph, and in the 2006

Italian Grand Prix, it was 152.749 mph. For our F1 car in a small scale we attained an

average speed of 1.769mps, which is a reasonable speed considering the weight of the

car. All these stats clearly demonstrate that the body design structure, durability and

reliability all considerably affect the overall performance of the car.


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Wheel Design for reliability and durability


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Virtual Model Flo analysis (Assembly)

This determines the impact of a liquid or gas on product performance during the

design phase using CAD-embedded solidworks Flow Simulation.

Virtual Model FEA analysis (Assembly)

Finite element analysis (FEA) is the modelling of products and systems in a virtual

environment, for the purpose of finding and solving potential (or existing) structural

or performance issues. FEA is the practical application of the finite element method

(FEM), which is used by engineers and scientist to mathematically model and

numerically solve very complex structural, fluid, and multiphysics problems. The

purpose of using FEA analysis in the formula one car was to solve any

potential/existing performance or structural issues, some of them which includes;

- Section areas

- Moments of inertia

- Plate thickness

- Bending stiffness

- Transverse shear

Types of analysis include:

Linear statics: linear analysis with applied loads and constraints that are static

Nonlinear statics and dynamics: effects due to contact (where one part of the model

comes into contact with another), nonlinear material definitions (plasticity, elasticity,

etc.) and large displacement (strains that exceed small displacement theory that limits

a linear analysis approach)

Normal modes: natural frequencies of vibration

Dynamic response: loads or motions that vary with time and frequency

Buckling: critical loads at which a structure becomes unstable

Heat transfer: conduction, radiation and phase change


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Design for Manufacturing (DFM) Dialogue with manufacturing

Successful mechanical design and engineering is environment and process

dependant. There are many factors that affect the design and its output. The following

are major factors;

1. Product choice difficulty

2. Time to market

3. Cost

4. Product competitive environment

5. Organization arrangement

6. Design engineering and manufacturing tools

7. Staff experience

Design for Assembly (DFA)

Design for Assembly recognises the need to analyse both the part design and the

whole product for any assembly problems early in the design process. Since it was a

group project to design a F1 race car, we divided among each other, and the parts that

we need to assemble was the spoiler and front wing.

Process Design and Development

The Putting the design and development together requires a lot of work and skill,

and the most important tool is the machine/s used in finalizing the design. Below is

the summary of the most important machine, the MakerBot

MakerBot 3D printing process:

The MakerBot 3d printing is the easiest, fastest and most affordable tool for

making professional quality models. The makerbot creation process starts with the

digital design, this can be a design you create using an individual program such as

CATIA and many more. If you’re using for example a program such as CATIA to

design your model, you must save your design as ‘stl’ file after completing your

design to be ready for printing out.


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The next step after completing your design is to open it in MakberBot maker ware

this is the software that allows you to prepare your model to be made on your

makerbot maker ware replicated tool. Makerbot maker ware is a software tool

developed to move and scale your model and to arrange just so on the virtual build

plate. When you just got how u wants your model to print out just click make it and

the makerbot replicator will begin transform your digital 3D model into physical 3D

model.

The material that the MakerBot replicator use is renewable bio plastic is called

“PLA”. When you tell the MakerBot replicator to make something, it begins by

pulling the PLA film at the back up through the tube and into the extruder.

The extruder heats it up and squishes it up through a very small hole on the build

plate. It starts by laying down the bottom layer of your 3D model, then the platform

move the object down a tiny bit so the extruder can lay down the 2nd

layer the process

continues for the next layer, and the next layer, and the next layer. This process can

take some times, because each layer can be as fine as 100microns.

The above photo clearly shows the makerbot program running on a computer; it also shows

the team model car


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The above photos show the final output of the F1 car. This was successfully done using The

Makerbot machine & program

Quality assurance:

MakerBot replicator is very powerful software helps us take the most advantage of our

powerful desktop 3D printing and scanning products in engineering and many more

other industries. As an engineer or any other particular person who willing to use this

software, you must be capable and strong with high attention to details the 3D models

and be able to maintain the MakerBot replicator. As quality assurance you must at

least have 1 year experience and knows how to develop the designs/models to ensure

you print the best model possible.

Dimensional analysis:

Dimensional analysis is one of the most important concept of physics and it’s really

important before starting on your design to have all the Dimensions of your model

correctly and have good understanding of them which are ‘length, mass, height and

etc.’ of your model in order to have a successful outcome. There are several types of

dimensions that we must be aware of during working on our design, such as how our

model will look as 3D and 2D.


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Product Validation

First of all the general idea of a product validation is the process of achieving an

increased certainty that a product idea/design will indeed be successfully adopted in

market. The showcased F1 car takes note of all the criteria’s involved with certain

successfully car models out there in the market today. For example it has wheel

bearing grease which helps with wheel position and maximum wheel utility, gearbox

lubricant this helps improve the overall speed, control and smoothness of the car. Etc.

The below picture further explains the ideas directly keyed into the F1 car model.


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Timeline of the F1 car development

This photo portrays 2 views of the F1 car model

The above photo clearly shows the front view and top view of the F1 car model

This photo shows the right side view and bottom view of the F1 car model; it also

shows the impeccable side designs and wheel alignment and size.


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Aerodymics analysis flow using solidworks

The above photo shows the flow simulation and also the size, dimensions and

conditions of our aerodynamic tested F1 car.

- Pressure generally within range of 101.05KPa and 101.65KPa.

- Higher pressure at front spoiler.

- Lower pressure under chassis and front spoiler.

- Lower pressure at nose and top of cockpit position

The photo above clearly shows a Virtual Model Flow analysis and other

related/relevant data


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Flow Trajectories

- Bigger pressure range between101.15KPa to 101.75KPa.

- Extremely high pressure at thrust face.

- Lower pressure just past front surface.

- Turbulent air flow at rear.

The above photo clarifies the flow trajectory of the F1 car.

This above photo clarifies the flow trajectory of the F1 car.

The above photo clarifies the flow trajectory of the F1 car.


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Conclusion

In conclusion as a group we can all agree that a lot of time, energy and strategy were

put into this Formula One car. Everything involved in our car from start to finish

conveniently fits within the required criteria, from the weight size length and most

importantly the aerodynamic/tests are almost perfect to a real life F1 car. This team

consists of 3 group members who are; Ehinomhen Oseghale, Atiqullah Ataei

Masood Naziri. During the initial designing of the project, a minor delinquent was

encountered which involved the weight. That was the only major problem we had, and

this resulted in slowing down of the car during race time. The improvement that could

be made includes, paying close attention to the criteria and required mass limit. It is

innocuous to say; together we are all individually proud of our effective contribution

towards the strategic building/construction of this F1 car. From the 1st week of initial

panning to the 12th

week of the final compilation of the entire project, it is more that

safe to say that the two main goals ‘Teamwork’ & ‘real industry experience’ were

both more than accomplished.


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REFRENCES

https://sopinion8ed.wordpress.com/category/is-success/page/2/

http://www.cgsst.com/eng/risk-factors/organizational-risk-factors.asp

http://www.engineerboard.co.uk/jobs/aerospaceavionicsandaeronautics/aerodynamicsfluids

http://www.engineersaustralia.org.au/resources-and-library

http://www.topgear.com/au/cars/reviews

https://sopinion8ed.wordpress.com/category/is-success/page/2/

http://www.cgsst.com/eng/risk-factors/organizational-risk-factors.asp

http://www.engineerboard.co.uk/jobs/aerospaceavionicsandaeronautics/aerodynamicsfluids

http://www.engineersaustralia.org.au/resources-and-library

http://www.topgear.com/au/cars/reviews

catia project (completed)

Documents