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- 1. Machine Design Group Project Formula SAE – Front Wing Mount Robert Peperkamp Tawanda Zhungu Manjula Gallella
- 2. Team Goals • 1st at Comp • 235 kg weight budget • Podium in every event • Lowered CG Height • 3 months testing
- 3. Design Goals (Aero) • Design all the structural aspect of the wing package so that it withstand all aerodynamic and dynamics loads • Easy maintenance of the wing • Have a minimum of 4 mounting points on the chassis • Reduce form drag created by the front tyres • Provide optimum downforce • Adjustability of the wing elements’ angle
- 4. Design Constraints • Total weight of 4 kg • A maximum deflection of 10mm, measured at furthest point from the chassis, in any direction at maximum loading • Should not interfere with other critical mounting points on the front bulkhead • The design should satisfy all the competition rules • The design should not increase the overall drag by more than 10% of the baseline model (without wings)
- 6. Weighted Matrix Design Aspects 1 (Low Importance) 2 3 4 5 (High Importance) Drag Reduction ✔ Downforce ✔ Fit in to the Weight budget ✔ Serviceability ✔ Use of standard parts (bearings, bolts etc.) ✔ Material Cost ✔
- 7. Initial Ideas • Ordinary Formula SAE Front Wing Courtesy: Team Swinburne Formula SAE 2013
- 8. Previous Year’s designs • Heavy • Not Aerodynamic Oriented. • Drag
- 9. Ts_12 Wing • Steel Bars and aluminium plating supports • “Foam Filled” wing • Total wing package weight ~15kg
- 11. Ts_13 Front Wing • Steel and Aluminium supports • 3 layers of carbon fibre • ~13.5Kg
- 12. Initial Ideas • A platform attached to the front wheel as a drag reduction method
- 13. Latest Design
- 14. Wing Profile Selection http://www.allstar.fiu.edu/aerojava/wing31.htm • University of Illinois at Urbana-Campaign (UIUC) Airfoil Data Site was used to explore the different wing profiles for the design. • Eligibility: High coefficient of downforce, Low coefficient of drag • Possible wing profiles: E423, S1223, CH10
- 15. Wing Profile Selection • Custom Drawn Profile (Similar profile)
- 16. Initial CFD run
- 17. Different Wing Settings at 50 km/h Downforce Drag Front Wheel Drag No Wings 0 0 15.6 1 Element -9.1 1.94 13.93 2 Elements -8.52 4.79 11.36 3 Elements -12.8 3.7 11.6 -15 -10 -5 0 5 10 15 20 Force(N) Wing Settings Comparison
- 19. Initial FEA run • According to the CFDs at extreme limits (120 km/h), the maximum downforce experienced by the wing was found to be 95 N • Rough weight of the front wing package = 3kg • Spar Design for the supporting wing
- 20. FEA Results • An initial FEA analysis was performed to see how the spar would behave under maximum loading • Downforce at 120 km/h • Maximum point load = 107.5 N • A Safety Factor of 1.5 • Weight of spar = 75g, Material = 7079 Aluminium Alloy
- 21. FEA Results
- 22. FEA Results
- 23. Plan for the rest of the semester Task Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Initial CAD Initial FEA Run Deflection Calculations (Based on track data) Selection of design Selection of Materials Coming up with the final design Final FEA Run Physical Testing (Spars) Presentation Project Report
Editor's Notes
- Heavy –More metals Lots of Drag. Vehicle could not finish endurance