© 2007 River East Transcona School Division www.retsd.mb.ca 589 Roch Street Winnipeg, Manitoba R2K 2P7 Tel 204.667.7130 Fax 204.661.5618

The F1 In Schools Design Challenge

What does it cost to introduce the F1 Design Challenge at my school? The program can be implemented through existing courses or as an extracurricular opportunity. Specialized 3D modeling software may need to be purchased but there are many different packages with a wide range of pricing. The main cost is the CNC equipment required to produce the car body. Many schools already have this technology and if the program is offered through a “hub” concept, one machine can service up to seven satellite schools to maximize cost effectiveness. Teachers need training on the software and equipment in order to assist students. Training takes about four or five days. Once school divisions develop this capacity, instructors train each other and these costs come down so the program becomes self-sustaining. Students tend to train each other once they become competent in these skills.

For more information about the F1 in Schools Design Challenge, contact:

David Woitowicz industrial arts/vocational/

home economics consultant for River East Transcona School Division

669-9412 or dwoitowicz@retsd.mb.ca

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Manufacturing Car Body - Machining Strategy

Since the car body we had designed contained areas that were not accessable with normal side machining processes we needed to solve the problem of how to remove this material.For the last four years, Bullets team members have used top and bottom machining processes for car manufacturing. The integrated CAM processing in CATIA is easily set up for 4 axis machining however we did not have a 4 axis router. Looking at the jig supplied with our Denford router it became clear that we could modify it to allow the balsa blank to be rotated at angles other than 90o.We manufactured a rotating fixture so that we could align the block at any angle we wanted.Experiments with CATIA showed that we needed to use a 4mm cutter at angles of approximately 650 and 350.Early prototypes showed that this technique worked but setting machine offsets had to be done with accuracy to avoid recutting already machined surfaces.

1. This image shows the 4th axis fixture set over to machine the 650 angle machining process. Note the two spigots on the front end of the car which help to stabilise the car body during heavy cuts.

2. This image shows the same machining process from the other side.

3. Here is a screen shot of the 650 machining process taken from CATIA. Note the red rectangle which restricts the machining tool path to an area just underneath the cylinder housing.

4. Here is the 350 machining tool path. Once again the red machining boundary reduces machining time and stops the cutter from possibly damaging areas of the model already machined.

5. This image shows the supplementary machining operation on the wheel openings. Using a 2mm cutter allowed the wheels to fit much closer to the car body. However the long slender cutter had to be run at a lower feed rate to avoid it breaking

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Prep and PaintOnce the car bodies came out of the router, it became clear that the preparation of the rough blanks would be a very challenging exercise. Manufacturing Engineer James, is well known for the immaculate finish he can achieve on F1 car models. Even so he spent an estimated 120 hours of preparation on three full size and one 2X scale model of the AC Racer. Some areas of the blank were almost inaccessible and had to be sanded with some ingenious improvised tools like custom made sanding blocks, cotton wool buds and steel wool balls. Dozens of coats of filler and primer had to be sanded back with care to avoid building up weight on the car bodies. The raw balsa blanks weighed 14 grams and after preparation they were just 8 grams heavier.

James sands back another coat of spray putty to fill defects in the full size race car.1.

The 2X display car after spot filling. Different colours are used so that James can see when most of the filler is removed to avoid adding mass.2.

The 2X aspirator and rear wing being sprayed with a small touch up gun.3.

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Car Body Machining Process

The photo at right shows four partly machined car bodies. The rear blank was created as a test piece to ensure that offsets were accurate. Any minor machining errors were tuned by making small manual adjustments in Z and Y offsets only. These bodies have been through the first three machining operations with a 6mm ball nose cutter. In all there are 15 different machining operations. (Some operations had to be repeated on both sides of the blank.)These are:

Side raster machining • Top raster machining• Bottom raster machining• 65• 0 raster machining with 4mm ball nose cutter35• 0 raster machining with 4mm ball nose cutterAspirator mount pocket machining with 4mm slot cutter• Tether guide pocket machining with 4mm slot drill• Wheel pocket raster machining with 2mm ball nose cutter• Axle peck drilling cycle with 2mm standard twist drill run at 3000 rpm.•

Tests showed that drilling at 23,000 rpm produced oversized holes as the drill whipped considerably. All raster machining operations were carried out with a stepover of 0.5mm to improve finish.

Note the extension on the rear of the cylinder chamber to protect the machining spigot. Note also the two spigots at the front end of the car body to prevent the blank from twisting during raster cutting.

What is the F1 in Schools Design Challenge?It’s an exciting and unique competition open to teams of students 11 to 18 years old, who use science, technology and their imagination to design and manufacture the fastest CO2- powered model race car. Teams race their cars at a regional competition. Winners can go on to compete at a national and worlds competition. Teams are judged on the speed and design of their cars, on oral presentations, and on their Formula One “pit” displays.

How does the F1 in Schools DesignChallenge work?Each student on the team is assigned one or more role:

• Team manager• Resources manager• Manufacturing engineer• Design engineer• Graphic designer

Using computer-aided design (CAD) and computer-aided manufacturing (CAM) systems, as well as computer numerically controlled (CNC) machines, team members collaborate to achieve their goal of producing the fastest model Formula One car. The use of virtual reality wind tunnel software allows the team to test and improve their car’s design. The car is a 1/20th scale model made from balsa wood and driven by compressed CO2 (carbon dioxide). Cars are raced side-by-side along a 20-metre track at a scale speed of over 220 mph.

For competition, the team must also prepare a “pit” display showcasing their marketing design and strategy, a portfolio and a five-minute oral presentation explaining their design and its development as it relates to the physics of a real F1 car.

How does the F1 in Schools Design Challenge benefit students?The F1 in Schools Design Challenge: • Helps students understand the relationships between science, technology, engineering and math.• Applies advanced technology to real engineering design challenges.• Makes connections across curriculum areas.

Students learn about: o Physics o Sponsorshipo Aerodynamics o Marketingo Design o Leadership and teamworko Manufacturing o Media skillso Branding o Financial strategy o Graphics

• Fosters an interest in engineering, science and technology, manufacturing, marketing and graphics. • Develops job-related “soft skills” as identified by business and industry. • Promotes self-directed, collaborative learning.

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Uniform DesignChoice of uniform is a crucial part of the presentation of any team sport or activity. AC Racing would need to have a distinctive and unique look in order to make an impression and to unite team members from different countries and cultures. Research of real F1 teams showed that the uniforms played a large part in the need to attract sponsors and fans. The BMW Sauber F1 team shown above left demonstrates the style of uniform that the AC Racing team wanted. Further research showed that race suits like these could be purchased but a full Nomex layered suit would cost upwards of $500 each.

In 2008 Bullets team members used a lightweight replica race suit and formula one style race shoes as the basis for their uniform to compete at both the Queensland State Championships and the National Championships held in Canberra, Australia’s national capital.This style of uniform was distinctive and unique however finding a supplier who would manufacture one in white was almost impossible. It wasn’t until team members paid a visit to Barnes High Performance, a local auto tuning centre and race component supplier that we were able to secure a deal to have custom made suits made to order by Revolution Race Gear at a subsidised price of $100 per suit.

Following on from the success of that uniform design the Australian team members went back to their old supplier with an order for six more suits. Four of these would have blue trims and two would have red trims (for the Canadian team.) Red shoes were also ordered for Canadian team members.

Shown at left are the Australian Bullets team wearing their replica race suits at the 2008 Australian National Championships in Canberra. Each suit was decorated with graphics and sponsors logos using inkjet printable iron on transfers

R A C I N G

R A C I N GR A C I N G

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Here are four different formats of the same logo.The two red stripes represent the two Canadianteam members and the four blue stripes for thefour Australian members. The AC typeface is areference to AC-DC (the rock band) The font iscalled Squealer.The texture on the RACING type is to representthe aluminium used to manufacture the wheels.#1 can be used as a sticker for the cars since itdoesn’t have the drop shadow and is mucheasier to render in CATIA#2 can be used on the uniform where thealuminium texture may not work as an iron onsticker#3 can be used in the folio and on businesscards etc.#4 can be used on the wheel covers

R A C I N G

Design Development and TestingTeam Branding and Marketing - continued

After considering all the prototype designs, the final format of the AC Racing logo is shown on the left. It was used on all team uniforms, this folio, the race cars themselves, the pit display and marketing materials used by the team.

Right: Ben and Canadian teacher director, David Woitowicz approving the design for the AC Racing uniform

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The TeamWe are AC Racing, an Australian / Canadian collaboration team formed by “The Bullets” and “Black Mambas”. The Bullets have competed in the Australian F1 in Schools competition since 2006 and this is our fourth year in the competition. Canadian team, “The Black Mambas” formed as novices in 2009 . By taking advantage of the collaborative partnership with Australia and drawing on over 15 years of collective experience the Black Mambas went on to win the Manitoba Provincial Championships and place thrid outright in the Canadian National Championships. One of the unique aspects of our team collaboration is the different level of experience between our two teams. When we began the eight month long journey to reach London it became clear that part of this process would involve sharing ideas, resources and expertise. In just two months members of The Bullets were able to mentor and support the Black Mambas to help them succeed with their goals in F1 competition. Our race history is impressive.

THE BULLETS:

2006 Queensland State Championships Best Engineered car - Junior Knockout winners - Best Team Collaboration - Junior Champions

2006 Australian National Championships Junior Knockout Champions - National Judges Award

2007 Queensland State Championships Junior Gold Medallists - Best Engineered Car

2007 Australian National Championships Fastest Car - Best Engineered Car - Second Place Runners Up

2008 Sunshine Coast Regional Championships Best Engineered Car - Senior Champions

2008 Queensland State Championships Senior Knockout Champions - Best Engineered Car - Best Team Collaboration - New State Record Holder - Overall Pro Senior Champions

2008 Australian National Championships Overall Pro Senior Champions

BLACK MAMBAS

2009 Manitoba Provincial Championships Senior Champions

2009 Canadian National Championships Third Place Outright

SCOTT BELLINGHAMTeam Manager

Scott is a tireless worker and a great team leader. Scott has a history of outstanding communications skills. He is also the dedicated starter for this team. Scott has proven skills in this area with reaction times as low as .008 of a second. Dependable under pressure, he can consistently produce fast start times again and again. Scott has created countless relationships with local businesses and he supports the team any way he can.

DEAN TSILFIDISDesign Engineer

Dean is hard working and reliable. His advanced skills in using CATIA and other ICT’s have been invaluable to the team. If Dean is set a task he is guaranteed to complete it with outstanding results. His creativity and innovative ideas help him to design exceptional cars. Dean is a team player who is willing to put in the extra hours to get the job done.

LUCAS RYKENBERGResource Manager

Lucas’ enthusiasm keeps the team optimistic and on task. He is always there to lend a hand and give support. His all round skills and willingness to learn is a benefit to the team.Lucas has been successful in finding over $7500 in donations and funding to help pay for costs associated with travel and accommodation. He also has brokered deals with suppliers of promotional products including thousands of bottles of custom labelled spring water and custom made chocolates.

JAMES PRESLINGManufacturing Engineer

James is the youngest in the team. Despite his age he is smart and can think outside the square. His skills in the workshop make him a natural Manufacturing Engineer. James can always create a great quality finish and high tolerance assemblies using a wide variety of hand, power and CNC machine tools. He is meticulous and creative in all aspects of manufacturing.

BEN KUILMANManufacturing Engineer

Ben is a keen and adaptable Manufacturing Engineer who has demonstrated an ability to learn new skills and put them into practice. Ben has put his ability to the test by machining, finishing and assembling a Provincial Final winning F1 racer in under two weeks.

STEPHANIE HIEBERTGraphic Designer

Stephanie is a creative and versatile illustrator, familiar with a wide range of digital and traditional media. Her software skills were put to the test with requirements for this year’s F1 in Schools collaboration project. Working across 13,500 km with industry professionals in Australia, she created many of the unique aspects of our presentation.

Top Right: The Bullets (from Noosa District State High School,

Queensland, Australia at the Queensland State Championships

where they finished as outright first place champions. They also won

several other major awards including Best Engineered Car.

Right: The Black Mambas (from Miles MacDonnell Collegitate in

Winnipeg, Manitoba, Canada) at the Manitoba Provincial Championships where they also finished as outright

first place champions.

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Design Development and TestingSmoke Flow Visualisation Testing and Results

In this series of tests we wanted to compare the data collected during CFD tests. In the photographs below we used a strong light to illuminate the streamlines of smoke making them easier to see against a black backdrop.

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PHOTO 1. In the image at left the streamlines passing over the nose and cylinder housing are clean and undisturbed. At the rear of the aspirator there is a small area of turbulence however because of the shape of the aspirator most of the streamlines are able to move slowly back to their original position. We believe this shows good flow characteristics and only minor turbulence.

PHOTO 2. This image shows the recirculating area of air directly behind the aspirator nozzle however the remaining streamlines show a very clean wake with little disturbance.

PHOTO 3. This image shows the streamlines dividing cleanly at the nose and the slight bow wave beside the front wheels.

PHOTO 4. This image is the one we are most proud of. It shows the streamlines rejoining at the rear of the body point. When we were considering the original design concepts, this was one of the goals we were trying to achieve. Our research showed that highly efficient aerodynamic shapes like aircraft wings use similar forms to ensure low drag and low turbulence.

Computational Fluid Dynamics Testing and Results

Analysis of aerodynamic data was carried out using a two different CFD programmes. The results shown here were taken from Phoenics Virtual Wind Tunnel however a separate series of tests were done using FloWorks. Our aim was to check for pressure differences over the surface of the car body and the space around the car.

PHOTO 5 shows the velocity vectors on the Y plane as air flows over the centre line of the car assembly. Since areas of high velocity create low pressure or suction, the aim would be to reduce high velocity areas at the rear end of the car. In the image, the green vectors are areas greater than 20 metres per second so these areas would also have the lowest pressure. Two large bubbles of low pressure can be seen just above the front axle and on the forward curve of the cylinder housing. The blue vectors at the rear of the car show that there is little suction at the rear.

PHOTO 6 shows another view of the rear end of the car and aspirator and the vectors are all showing low velocity which equals high pressure.

PHOTO 7 shows the Y plane again with pressure showing as coloured bands. The same areas indicated by the high velocity vectors are now shown as low pressure. There are two small areas of high pressure where the air is compressed ahead of the cylinder housing and the front wing but because these are kept as small as possible, the airflow here should slide smoothly over these areas.

PHOTO 8 shows a group of streamlines flowing over the cylinder housing. Once again the airflow divides easily and rejoins at the rear of the aspirator with little turbulence.

HIGH VELOCITY

LOW PRESSURE

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