THRUST VECTOR Embrace Opportunity, Create Reality Western Sydney - - PowerPoint PPT Presentation

THRUST VECTOR

Embrace Opportunity, Create Reality Western Sydney Regional Competition, Engineering Presentation

THRUST VECTOR

Embrace Opportunity, Create Reality

CAD

SELECTION OF CAD SOFTWARE

➔ OnShape ➔ Cloud Based, Everyone Can Access It ➔ Powerful Parametric Modelling ➔ Compatible With Other Programs ➔ Quality STL And STEP Exporting ➔ Automatic Saving ➔ Mobile Versions

CAR DESIGN REQUIREMENTS

➔ Easily Assembled ➔ Lightweight ➔ Aerodynamically Streamlined ➔ Reduce Rolling Resistance ➔ Reduce Skin Friction ➔ Reduce The Low Pressure Void ➔ Comply With Regulations

CAD APPLICATION

➔ 2D Sketches- With Dimensions/Constraints ➔ 3D Geometry - Extrudes, Revolves, Lofts ➔ Refinement - Fillets And Chamfers

CAD APPLICATION

➔ Assemblies - Mate Connections, Orientation, Exploded Views ➔ Technical Drawings - Labelling, Formatting ➔ Rendering - Material, Lighting, Size

CAD ORGANISATION

➔ Named Tabs & Workspaces ➔ Version Control ➔ Shared With Team Members & Teacher ➔ All Can Access Up To Date Files

CAD BASED ANALYSIS

➔ Regulations Checks ➔ Volume/Mass Checks ➔ Virtual Cargo Placement ➔ Computational Fluid Dynamics

CAD BASED ANALYSIS - CFD

➔ SimScale ➔ Works Directly With OnShape ➔ Justified Breaking Regulation T4.3 ➔ TVC2 had 0.575 newtons of drag, while TVC4 had 0.344 newtons of drag.

THRUST VECTOR

Embrace Opportunity, Create Reality

CAM

SELECTION OF CAM SOFTWARE

➔ Deskproto ➔ Produces G-Code Using STL Files ➔ Compatible With All CAD Programs ➔ Works With Multiple Types Of CNC Machines

APPLICATION OF CAM/CNC

➔ Use Of A Machining Support Block ➔ Top/Underside Cutting ➔ Cut Along X Axis ➔ Took Off 2mm Per Pass ➔ Roughing Set To 0 ➔ Expanded Border To Make Sure The Edges Were Machined ➔ Roughly 30 Minutes Per Side

CAR BODY MANUFACTURING

➔ Used Custom Jig ➔ Fitted Block To Jig ➔ Wedged Wood & Plastic To Stop Block Rotation ➔ Manually Position Cutter To Origin ➔ Load G-Code ➔ Start ➔ Repeat Above For Other Side ➔ Collect Rear Wings ➔ Glue On Rear Wings

FRONT WING MANUFACTURING

➔ 3D Printing ➔ Load STL Into Software ➔ Configure Print Settings To 5% Fill Density & Export ➔ Transfer To Printer Via SD ➔ Begun Printing With ABS ➔ Warped & Ruined Print ➔ Used PLA Instead

OTHER MANUFACTURING

➔ Cut Carbon Fibre Axles ➔ Put On Tether Line Guides ➔ Inserted Grommets ➔ Wheels Glued Onto Axles ➔ Sanded Sprues Off Wheels ➔ Constantly Weighed Cars ➔ Checked Cars With Manufacturing Tools We Produced

TOLERANCING/QUALITY CONTROL

➔ CAD Design Accounted For Error ➔ Check Regulations Before Manufacturing ➔ Collaboration Between Design & Manufacturing Engineers ➔ Select Block With Most Optimum Mass ➔ Constantly Weighed Car ➔ Check Deskproto For Errors ➔ Check 3D Printing Software For Errors ➔ Run ‘Air Test’ Of Beginning Of CNC Process

SURFACE FINISH

➔ Hand Sanding, To Remove Machining Marks ➔ Wood Filler, To Fill Dents & Divots ➔ Spray Putty/Primer, For Smooth Finish ➔ 2-4 Coats Of Paint, For Desired Finish & Mass

THRUST VECTOR

Embrace Opportunity, Create Reality Western Sydney Regional Competition, Engineering Presentation