Newsletter february 2013 by Formula Student Team Delft

DUT racing team

Newsletter February

ÂŠ Kroeger (FSG)

Content - Introduction - News - Kick-off Production - interview with an engineer

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Introduction

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Four months ago we started designing the DUT13 and now we have come to the point of actually building it. In this newsletter we will give you an update about the current status of the development of the DUT13. The design of all the separate parts is nearly finished. Monday the 4th of February was the first day of a new phase of

ÂŠ Paul Brussee

building the car, namely the start of the in-house production! While the in-house production has only just started, some out-sourced parts like the monocoque moulds have already been manufactured. A great milestone for the chassis department!

In this newsletter you can also learn more about some of our sponsors in the full stories of our visits to Fokker Aerostructures and TBP. In short, another very exiting month, I hope you enjoy reading!

- Marius Knol, Team Manager.

News

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FSUK and FSE

Here we come!

It is definite! We will go to both FSUK and FSE! The subscription for FSUK, which will be held on the Silverstone Grand Prix circuit, is fully completed. We expect to finish the subscription for FSE, that will be held at the Hockenheimring, very soon. The event in the UK will take place from the 3th up till the 7th of juli. The FSUK competion was actually the first competion in which DUT Racing competed over 12 years ago. It is now one of the biggest and most competitive competitions in Europe. As this has always been the event where DUT Racing would introduce their car to the race track, it is also the event where most problems come will come to light. So this event is a very important step to have the

car running perfect for the biggest competion for electric Formula Student cars: FSE. The FSE competition will be held from the 30th of juli up till the 4th of august and is renowned for having the most competitive field of electric racing teams. We expect a lot of competition from around the world

“The business of perfection”

This year TBP works together with DUT Racing in the design of the circuit boards for the Electrical Control Unit (ECU), the dashboard, the sensor nodes and they will

and hope to continue the excellent trend of results into the 2013 season. We also have the first spot on the waiting list for the FSA competion at the Red Bull ring in Austria. So it might be that the DUT13 will become the second DUT Racing car after the DUT08 to compete in three official events. © Kroeger (FSG)

Another new sponsor. TBP, When assembling a circuit board, a lot more is involved than simply soldering electrical components. That has become very clear during a visit to TBP electronics. TBP is the place to be for all kinds of services in the field of electronics, from design to distribution.

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also be responsible for the final assembly of these components. The functionality is completely designed by the team and TBP will help us to ensure an optimal manufacturability and testability of the print, so that a very reliable product will be created. “The Business of Perfection”, where the acronym ‘TBP’ stands, is very keen on providing products with a high level of quality. The presentations showed that every detail that can go wrong has been

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Fokker Aerostructures, one of our new sponsors

We found the visit very valuable, and are looking forward to the further relation and cooperation between Fokker Aerostructures and the DUT Racing Team!

Contrary to what most students should become ‘200 years Fokker’. think, Fokker Aerostructures isn’t dying, but alive and kicking! The best thing about our Fokker visit today, was to see how Four members of our team went to enthusiastic the design engineers Papendrecht for our first meeting of the company are about the DUT with the engineers at Fokker Racing Team, and how eager they Aerostructures, one of our newest are to integrate their expertise in our car. The door to the extensive sponsors. knowledge and help of Fokker ‘Have fun’ is where it’s all about, Aerostructures is wide open, which according to Theo de Graaff, will certainly help us realizing our Senior Design Engineer at Fokker car. Aerostructures. Also, continuity and growth are very important goals of Fokker; ‘100 years Fokker’

thought through and this of course is important to make the prints testable. During the presentation, there was also a representative of JTAG, who explained the effective method of “boundary scan”. We also had to chance to talk to representatives of Transfer, who could answer our questions about the software Altium. With the gathered information, we can further improve our designs on our electric systems.

correct component has arrived and whether it is delivered in the correct orientation, so that it will be installed correctly later in the process. The components are then saved by an automated shuttle warehouse system. At the production department we got a glimpse of the high tech machinery used for assembly and testing. Especially the high speed and incredible accuracy of the tools used, was very impressive.

After the presentation, we also had a tour around the production facility of TBP. With the arrival of a component at TBP, it will first be thoroughly checked that the

All in all, we thank TBP for their time to show us what they do and we are confident that our collaboration with TBP will lead to a good result!

Production Kick-Off After 4 months of designing the DUT13, the production period started of last week with a delicious “kick-off ” breakfast. After this, the milling and turning machinery started running on full capacity. Besides the machining of metal, production of the carbon fiber monocoque also started.

monocoque On Monday, January 21, Model en Matrijzenmakerij Twente (MMT) started milling the mold for the carbon fiber chassis. This is the first step in a long and complex manufacturing process. Ultimately, it is intended that the chassis, which is the largest part of the car, will be finished on the 1st of april, so that the assembly of the race car can then begin. But before this will happen, a lot have steps have to be done first. Out of MDF boards, two positive moulds are milled. The two moulds represent the top and the bottom of the monocoque and have the same shape as the monocoque will eventually have. The wood is sanded and treated with a primer, so that the negative carbon fiber moulds can be produced.

so called ‘pregreg’ fibers are dilivered at DUT racing, and know waiting for their part in this proces. Between the inner and outer layer of Textreme® fibres a foam core is placed. In this way, a very light and rigid sandwich structure is generated The whole monocoque These negative moulds then is estimated to weigh less than 20 represent the outer layer of the kilograms! chassis. For the monocoque we use Textreme ® fiber which will be laid After the two halves of the upon the negative molds. These moncoque have been created, they fibers give greater design freedom will be laminated on each other. as well as a higher stiffness than Then the holes may be drilled so conventional carbon fibers. These that all the other parts of the car

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can be attached and then the monocoque will be finished. Applying a nice paint job is the final step, but before that, there is still a long way to go.

metal machining Besides producing a composite monocoque, we also produce a hugh amount of aluminium and steel parts. This means a lot of turning and milling in the coming months to make the computer designs into real parts. This month we had the aluminium delivered by TATA steel and ODS. After a brief introduction course to learn the basics of the machinery, our team members started of producing. The first parts that are finished are the mounts that connect suspension to the chassis. As these components are subjected to all the forces that are exerted on the wheels, we made these components of a high grade of aluminium.

This type of aluminium is not only capable to cope with high forces and is not only very light, it is also a good material to work with as it is easy to shape. This will improve the accuracy and quality of the parts. Not only the

above mentioned mounts are made of this type of aluminium, but actually most of our metal parts are made with this product. We try to make as much parts ourselves as possible, but for some parts we just miss the machinery or skill. These parts include the uprights, sprockets and parts of the steering system. Luckely we can rely on some loyal sponsors that do have the capablity to make these parts up to a high standard. As was earlier mentioned, we have a lot of work to do the coming months, leading up to the events in the UK and Germany. But preliminary planning tells us that we will finish the car well in time so we can test s much as possible.

Interview with an engineer

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Formula Stude How did you end at DUT Racing? Iâ&#x20AC;&#x2122;m a huge motorsports fan and I follow each kind of racing, from Dakar to Formula 1, from Le Mans to the Indy 500. So I thought to myself; why not join a trophy winning team like DUT Racing? This way I can learn everything about building a proper race car and nicest of all: also racing it!

Name: Stefan Hertgers Nickname: Henk Study: Aerospace engineering 5th Years DUT experience: 1st year Task: Aerodynamica productie monocoque

What do you do within the DUT Racing Team? Within the 13th DUT Racing Team I am responsible for the aerodynamic design of the car. First I have worked on the general concept of aerodynamics and as the concept was determined my main responsibility became the under body design of the car. This involves shaping the bottom of the car in such a way that eventually down force is created in a very efficient way.

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ent Team Delft How does this fit into your field of study: Aerospace Engineering? Currently I am doing my master in Aerospace Structures and Materials. Now you might think why I am doing the aerodynamics design and not the monocoque for example. For my master I am specializing in the interaction between structures and aerodynamics in the so-called field of morphing structures. As my master is mainly concerned about the material aspect, this year of aerodynamics is a good source of (practical) information. And aerodynamics is still a very interesting topic of course.

What is the most unique about DUT Racing? The last 2 years the DUT Racing team has almost won almost as many prices as the first 10 years of racing. This means that there is pressure to perform. To reach such a level of performance the approach is very fundamental, something I really Is it a valuable addition to your like. And despite this fundamental study? approach and the large pressure For the next half a year I will upon us the working environment is produce the monocoque. With this still nice and enjoyable. activity I aim to gain some practical advantage in the production of composite structures. I do not obtain this kind of knowledge in classes, so this production is very valuable for my further professional career. Furthermore Iâ&#x20AC;&#x2122;ve also learned how to not work just an assignment, but in a team on a real object. I also go through the entire design process, considering the designing and manufacturing (which is more challenging than you think in the first place). Especially for me as student at the faculty of Aerospace Engineering in which actual practice, like e.g. milling, in production is missing. Now I learn how to do it during my time with DUT Racing.

Where do you see yourself in 20 years, and how will your experience with DUT Racing help you with that? I want to become a specialist in designing, with structures as a focus point. With the DUT Racing experience, like designing, I hope to have more experience in design. Also practical working experience is a great benefit to design something great! It might be the car you drive within 20 years!