April Update

Melbourne F1 GP

Fuel Tank for Production

One of the hardest things about design is when you have to actually make it! Design for manufacture (DFM) is the process of redesigning a concept into something that can be manufactured. This is the process the VUM team has been dealing with over the last couple of months for the fuel tank.
We have had a general form since January, but it really has only been since the August when the realisation came that the team is going to have to out source production. As with any out sourced task communication is the key to successful outcome. The call outs were made and we started chatting with a custom fuel tank manufacturer in QLD,  he provided tips and suggested processes to use. One of the major changes we had to make to the general form was to redesign the pattern so it could be folded out of 5000 series aluminum. Considerable amount of time was spend considering where the fold lines should be and how the individual parts should be joint (TIG welded).

Alloy Fuel Tank_VUM14_04092015

The follow link is to a zipped file to the Solidwork 2014 fuel tank CAD Files and Mechanical Drawings for Production 07/09/2015:
https://drive.google.com/file/d/0BzvDCEcFLEusU0JaM2JvZklnaTg/view?usp=sharing

Below is an embedded video of the fuel tank simulating the intended method of folding before welding:

VUM Workshop Surface Modelling Using Solidworks

Today is the day!

Abstract from College of Engineering Newsletter: 

Victoria University Motorsport's (VUM) contribution to National Science Week was the second in the “students teaching students series” of Solidworks CAD Modelling. Mr Nick Owen once again was facilitating the workshop titled “Introduction to surface modelling using Solidworks”. Students and academics took part enhancing their skills and knowledge on the subject. This was done using a guided demonstration method where the students learnt by doing or in this case “clicking”. Participants were walked though surface modeling, explained how to work within a 3d Sketch, set reference planes and use loft extrude and surface fill features. Once the surfaces had been configured the students specified a thickness to the surface. Without a surface thickness most simulation will fail, including CFD and FEA. Students ranged anywhere from 1st year to post graduate level, mixed gender and multidisciplinary. Not only mechanical students need CAD in there lives, anyone that has the desire to create, imagine and design should have the tools and knowledge to turn there ideas into designs this is what the series of workshops aims to do!

Lego Race Car_VUM15_20082015

Click the link below to download the zip files for the VUM Introduction to Surface Modeling Workshop using Solidworks: 
CAD Files For Workshop

Steering Quick Release

Back in 2013 when the team was designing and fabricating the VUM13-Sherman racecar, we were trying to save as much money as possible one of the items we skimped on was the steering quick release. Couple of dollars saved led to almost two years of headace, the team was first presented with the problem of steering slop at the 2013 FSAE-A competition and in 2014 we had a bright student try and design a new steering quick release. This year in 2015 we finally bit the bullet and purchased a FSAE / Formula racing steering quick release. Sure it cost more money but we finally have a quality outcome.

Quick Release_VUM14_19082015

College of Engineering News Letter

Design of a Rear Spring and Bellcrank Mount

Design of the rear suspension is based around two springs and dampers. Bellcanks translate the motion of the A-arms into the springs. The fore mentioned parts are detailed in the image below.

 

The first iteration focused on the geometry as the primary purpose is to support the spring and bellcrank. As the design choice was made to construct the part from 3mm steel plate, the assembly was deemed too heavy.

 

Inspire was used to optimise the structure, based on pre-defined loads from the bellcranks and springs.

 The structure was also analysed using Finite Element Analysis (FEA - Solidworks)

It was found that the original iteration could be optimised as no point of the structure exceed the materials yield point.

 

Altair Inspire was used to optimise the geometric shape, 

 The opimised output fom inspire was then translated into a new bellcrank and spring mount side plate, this resulted in a >1Kg weight reduction in the overall assembled structure.

 

 Laser Cutting of cardboard was used to physically evaluate to model before making it out of steel. A good thing we did this process as we made some minor adjustments that made fitment easier.

 The Final assembly was cut from 3mm steel plate, using a plasma CNC cutter (courtesy of VU-Foundation Studies).

The completed rear bellcrank and spring damper mount, placed onto VUM14 Mezza May before welding

Final Comments: The process of design though to development has been a fruitful process. For future iterations of this design more time can be spent of optimisation to reduce weight. In whole this was a fruitful learning experience.