9 20
11 7
18 8
6
3 4
10
14
12
15
13
5
3 Team Identity 4 Car Presentation 5 Sidepod Development 6 Canister Development 7 Rear Airfoil 8 Front Airfoil 9 Overall Analysis 10 Orthographic Drawings 11 Car Renders
12 Car Milling - CITEVE 13 Car Painting - FORD HERMOTOR 14 Car Assembly- LOJA 5 15 Time Management 16 Budget 17 Marketing 18 Pit Display 19 Sponsors 20 Evaluation
17 16
19
Team History
Team name and slogan
‘’Mustangs’’ were born on December 2013. All started in a physics class where our teacher told us about F1 in Schools. The idea of creating our own miniature F1 racing car made us very excited as we saw the dimensions of the project and all the skills required to enroll it. Although frightened by the time-consuming component, we decided to accept the challenge and we could not have made a better decision.
We wanted our name not only to represent one of our main sponsors but also to be unique and transmit our qualities. For one side ‘’Mustangs’’ is a tribute to Ford Hermotor and for another was inspired by the common characteristic features between our team and the horse Mustang: wildness, resistance and strength. Combining these particularities of the Mustang and the three main processes in the project, think, try and do, we came up with a slogan composed by three elements, as the team : - Be the wild thinker, the resistant trier and the strong doer -
Logo Development Inicially our logo was very basic, just inspired in the original Mustang car logo as we were still in a very young stage of team identity development. We then tried to implement a reference to the three elements of the team, and this way we decided to go for three horses instead of just one. After some more brainstorming, we finally finished our logo, full of significance and uniqueness as we aimed for. We fully redesigned the horses in order for them to incorporate the capital ‘‘M’’ of the team name, giving the logo a more cohesive style. We also replaced the horses’ bodies by a racing flag so the logo design would be associated with the racing world.
Ana Rita Pereira - 17 years old, scout, future computer engineer Team Manager: Rita manages the team work, by scheduling regular meetings and setting up deadlines. She is responsible for making sure the main and the substitute cars are ready in time for the finals. Resource Manager: Responsible for the merchandise, the acquisition of materials needed and also for maintaining contact with our sponsors. Rita is an essencial element in the developing of the marketing strategy of the team.
Pedro Costa - 18 years old, swimmer, future computer engineer Design Engineer: Responsible for the style and aerodynamic performance of the car as well as its analysis in virtual wind tunnels. His tasks go from designing the rear and front airfoils, car’s body and sidepod till the analysis of each part, modifying them if necessary. Pedro is the one who passes the team visions and concepts from the paper to Inventor.
Ana Andrade - 17 years old, painter, future theoretical physicistGraphic Designer: Responsible for the team identity: color scheme, design of the logo, car, portfolio and pit display. Ana creates the marketing materials to promote the team image. Manufacturing Engineer: Ensures all the rules are being respected during the design and manufacturing of the car. Is responsible for the materials used during the manufacture.
M U S T A N G S Color Scheme Silver as main color. Why ? - It symbolizes the modernism, class, new technologies and success. - Is a light color, not very tiering for the eyes. - Is the color of the original logo of the car Mustang.
The team also has secundary colors: blue and orange. BLUE is the color of FORD HERMOTOR - main sponsor. ORANGE is the color of MIBELA - main sponsor. The two orange stripes represent the girls on the team, Rita and Ana, and the blue one represents Pedro. Blue and Orange are also the colors of our school - Didáxis.
3
1
Get in touch with our car, literally !
The Stradivarius 1.0 3
Balsa Wood Car Body Our car is made of extremely porous balsa wood, making the car very light, weighting just 17g when it was milled.
Nylon Wheels We used nylon for the wheels due to its high tenacity fibers, high elongation; high resilient and good specific strength.
2
4
1 Rear Airfoil 2 Canister 3 Wheels 4 Axles 5 Sidepod 6 Bearings 7 Front Airfoil
5 6
Professional Car Painting - Two coats of primer; - Two coats of different colored ink; - One coat of polishing spray.
7
In the end, seen from above, our car was similar to a violin so we named it Stradivarius since the violins made from the Stradivarius’ family have the reputation for being the best ever made.
4
Concept Development Our first side pod attempt was based on a straight concept aiming to keep the airflow constant after its first cut by the front airfoil. The inside design of the side-pod consisted on a small angled opening which would redirect the air to the bottom of the rear wheels in order for the air to flow in the same direction as the rotation of the wheels. This way we compensated the pressure that was being putted on the top of the wheel surface. Problems : The airflow analysis of this part of the car revealed unsatisfactory results since the air was not being redirected as we previously envisioned. Solution : We decided to start from scratch and redesign a new side pod. This time we went for a more rounded shape based on the teardrop and formula 1 real cars. With our new car shape, we took advantage of the compulsory 15 mm of empty space behind the front wheels to make a more fluent and integrated overall shape of the side-pod with the rest of the car. Rear-side pod The rear side-pod was designed to be a continuous part of the rest of the car body by having the same cut angle on the top as the car body and adding a small angle cut to the bottom to give an escape to the air that flows under the car. This also created a low pressure zone that would generate a small lift force pushing the car forward. Research When making car designs more aerodynamic, engineers look to the most aerodynamic shape in nature: the teardrop. The teardrop has round, smooth sides that taper off. This configuration is ideal for allowing air to flow by easily, passing around its smooth edges and falling off gently at the end. Cars that closely follow this pattern are the more aerodynamic ones. Source: Discovery channel
5
Concept Development As our first inspiration we directed our attention also to a teadrop shape. So taking this into consideration we made the canister long, rounded and with a decreasing thickness, from the rear of the car to the front of it, so that we could achieve the best integration with the rest of the car body. This allowed the car to cut the air seamlessly and take advantage of a more adjusted mass center due to the more equally distributed mass of the canister throughout the whole car. After analyzing our first car we noticed that the angle of the canister directly influenced the overall drag of the car. Bearing this in mind, we decided to decrease the angle as much as possible and to do so we redesigned the canister so as to it would be from the tip of the car till its end. We also made it rounder in order to make it as alike as possible to the teardrop shape by rounding the bottom of the canister and therefore allowing the air to flow more efficiently. This of course showed a significant improvement in the amount of pressure the canister suffers. When concerning the dimensions of the canister we kept these to the minimum allowed leaving just a small margin of error (+/- 1,5 mm) for the manufacturing process. Problems: Since we were not familiar with Inventor 2014, it took some time to make the desired shape for the canister. Solution: Invest some time learning to work better with Inventor 2014 untill we were able to achieve the shape we were looking for. Research Given the problem of the aerodynamic design of the nose cone section of any vehicle or body meant to travel through a compressible fluid medium (such as a rocket or aircraft, missile or bullet), an important problem is the determination of the nose cone geometrical shape for optimum performance. For many applications, such a task requires the definition of a solid of revolution shape that experiences minimal resistance to rapid motion through such a fluid medium, which consists of elastic particles. A significant factor is friction drag, which is largely dependent upon the wetted area and the surface smoothness of that area, that’s why our car paint is coated with varnish to keep it as smooth as possible. The comparison of drag characteristics of various nose cone shapes in the transonic to low-mach regions can be seen on the right. The table clearly suggests that either the Von Kármán shape, or Power Series shape with n = 1/2, would be preferable to the popular Conical or Ogive shapes, for this purpose. We decided to go with the best shape so we used a Von Kármán nose cone shape in our cannister.
‘‘ Be the wild thinker (...) ‘‘
Rankings are: superior (1), good (2), fair (3), inferior (4).
6
Concept Develoment This part of the car did not change much because before designing it we did a lot of research on what would be the best design. We excluded the design being used on F1 cars because they had a different purpose than ours. We just wanted the rear airfoil to be a stabilizer of the car and so we decided to redirect our view to the wings of the aircrafts and see how they worked. And so we designed an airfoil similar to the wing of an aircraft. We also had winglets to the tip of the airfoil since this small detail is known to reduce the vortexes that regular wings create. Problem : Our first rear airfoil was simple, straight and with a small backwards inclination. Its problem was creating small vortexes. Solution: Our final rear airfoils were based on the commercial air planes, which have winglets on the tips so as to reduce the drag caused by these vortexes. Besides adding winglets we made them rounder and sharp for better cutting the air.
The only change was the conection of the airfoil to the car body to make it more secure. Research Winglets were wind tunnel tested and computer analyzed by Richard Whitcomb of the NASA Langley Research Center in the mid 1970’s. “Induced drag is a three dimensional effect related to the wing tips; induced drag is a wing tip effect. So if the wing tip represents only a small fraction of the total wing area, the induced drag will be small. (…) The idea behind the winglet is to reduce the strength of the tip vortex and therefore cause the flow across the wing to be more two-dimensional. Flight tests at the NASA Dryden Flight Research Center have found a 6.5% reduction in the fuel use of a Boeing 707 type airliner when using winglets.” We also turned our attention to the aspect ratio of the rear wing. In aerodynamics, the aspect ratio of a wing is essentially the ratio of its length to its breadth (chord). Low aspect ratio wings are usually used on fighter aircrafts, not only for the higher roll rates, but especially for longer chord and thinner airfoils. On the other side high aspect ratios provide great cruise efficiency but can have poor landing characteristics - high drag at low speeds or high angles of attack due to frontal area - that are often offset by high-lift devices like flaps and slats.
Boeing 707
Boeing 737
So we went for a airfoil with a very low aspect ratio to reduce the drag and not to have a high angle of attack. After designing our rear airfoil we calculated its aspect ratio and compared it with some aircrafts. Source: NASA Website - http://www.grc.nasa.gov/WWW/k-12/airplane/winglets.html
The Stradivarius 1.0 rear wings
F-16
F-22
Aspect ratios
Calculating the a.r. of Stradivarius
Boeing 707 - 7.1 Boeing 737 - 8.3 F-16 - 3.9 F-22 - 2.1
Aspect ratio = = surface area/ (length)^2 = (24,41 ×14,85)/(24,41)^2 ≈ 0,6084
7
Concept Development Our initial goal with the first front airfoil concept was to create an object that would redirect the air towards the parts of the car that we wanted. So we divided the front airfoil in 3 parts, being the middle of the airfoil intended to simply cut the air and the sides of the airfoil to redirect the air to the bottom of the wheels helping on the rotation of these. Problem: This first airfoil did redirect the air as we envisioned but not in an efficient way. Also it was a large block with notorious angles causing a lot of drag. So we decided to go for a smaller airfoil. Solution: We extended the car body being this part the one that cuts the air, and had small airfoils to the sides of the car to reduce the pressure that it is created on the wheels. These smaller airfoils on the side of the car proved to be more efficient, due to being a small piece and therefor causing less drag, in redirecting the air in front of the wheels. And by using the car body as and airfoil for the air that passed in the middle of the car we could get a more fluent shape and make the car more aerodynamic. Bellow you can see the comparison between the Stradivaius and a F1 car.
F1 Car
The Stradivarius 1.0
8
General Considerations In the designing of our final car we decided to research more about aerodynamics and how F1 race cars and aircrafts are designed. We then designed the front airfoils as small as we could in order to create a minimum amount of drag while deviating the air flow from the wheels releasing these from high pressures. The rear airfoil was based on a totally different concept. We realized that a simple airfoil would create vortexes, so we did some research and found out that aircrafts had winglets in the tips on the wings in order to reduce this vortexes and had a more fluent air cut. So we decided to also include this in our car. Car Technical Specifications Family - Stradivarius Série - 1 Version - 0 Creators - Pedro Costa, Ana Andrade and Rita Pereira Units produced - 2 Fueled by - Compressed CO2
Dimensions (mm) (Expected - Real) Width - 79,32 - 80 Height - 58,02 - 58 Length - 205,31 - 201 Weight (Expected - Real) - 55 - 75 (g) Drag - 0,56 Aspect ratio - 0,6084
Colors - Silver, Ford’s Blue and Mibela’s Orange Stickers - Ford Hermotor (left side) ; Mibela (left side) ; Didáxis (right side) ; Portuguese Flag (right side) ; F1 in Schools logo (right side) and capital ‘‘M’’ from the team name (in each wheel).
9
10
11
The first step to turn a piece of wood into a car is to model it. For that we used a 3 axes machine provided by CITEVE. Altough, as our car design just has components in the X and Y axes we just needed to use two axes, meaning this that we just had to turn the car once on the machine. Preparing the Machine To our original car Inventor file we needed to add an extra milimiter plan so it would be possible to calibrate the machine and locate the car in space so the machine would know where the wood was and so, properly model the car. In this phase we had the chance to learn more about 3D modeling, for example, we learned that if the machine was not well calibrated just by just 1 cm, when modeling, the drill would get out of the wood and model its support and probably also damage the machine. Fortunatly we had help on his part and all went as planned. Defining the Working Plan The next step was to define a working plan. A working plan tell us how many times the drill will pass on the wood to full model the car. Due to the thickness of the drill and the dimensions of the car, just two passages were enough. Converting Files A FNC file needed to be created once that the machine could not read Inventor files. And before the machine could read the file, a program called VR Milling 5 converted the file into 18 809 code lines that could now be read by the machine. This part made the team very curious once that we did not know this procedures before. Car Milling Now, that everything was ready, it was time to start the modeling of the car ! As the machine was modeling the car we could see in real time the code lines being read on the computer. After all the codes lines were read, the right side of the car was ready. Posteriorly the left side of the car needed to be modeled as well, exactly the same way. For this the comand M71 was inserted in the program where were the code lines to make the machine do a simetry in the Y axle and model the remaining wood. Problems : As the drill was too thick we did not had to chance to do the axles wholes simultaneously to the car milling. Another consequences of the thickness of the drill were the imperfections and not as much detail on the wood. Solutions : To solve the axles wholes problem we turned to one of our sponsors - LOJA 5 - where a smaller and adequate drill was available to do them with detail. The imperfections on the wood were solved by sanding the car and further covering it with two coats of a primer spray. Airfoils CITEVE was also the place where we printed our airfoils. Our initial design for the front airfoil connection to the car was not very safe and we were in doubt about its dimentions, so CITEVE gave us the chance to print this design and analise it. After considering the subject we redesigned the connection of the front airfoil to the car body and later sent it to CITEVE for printing in ABS. On the right you can see the printing and final result of our first front airfoil design and also the final front airfoils.
12
When we arrived at FORD - HERMOTOR, we had the chance to talk to all the staff involved in our car painting and to understand and discuss each phase individually. Painting Phases - Sanding; - Applying a primer; - Applying the base coat; - Applying the clear coat. Sanding The aim of sanding the cars was to take away small imperfections on the wood in order to give the final result a more professional look. Other major imperfections were corrected with filling material. Applying the Primer The primer had the goal to smooth the surface of the car so that the exture of the wood was not noticeable. Two coats were sprayed on the cars and, as the materials could not handle to much heat, dryed during the night instead of being applied radiation to fast dry them. Problems : Our first problem was the weight that the painting materials would put on the car, when the staff warn us that the primer was an heavy material. Even though the sanding would take away some weight we were not sure it was enough. Solutions : Our first tought to solve this problem was not to aply the primer, but after discussing its importance we decided that it was an important component considering its influence in the final quality of the car painting, once that the porous nature of the wood would affect the painting on a notorious negative way. So the staff tried to make each layer of primer, paint and polish as thin as possible so we could have quality on the final painting but also so we would not be penalized for possibly extra weight. Car Painting The next morning the car was ready to paint. We had delivered a color scheme of the car in advance and then it was just a matter of deciding how the paint would be applied. The staff suggested to paint the whole car silver at first and then had the blue details as it was easier, and the team agreed. Polishing Spray Finally, it was applied a clear coat on the cars to give them a shiny look and also to make them more aerodynamic, as the polish reduces the friction between the cars surfaces and the air. Unfortunatly the team could not be present in the final part of the car painting.
13
Loja 5 sponsorship was a valuable help in the manufacturing of the car. Before the milling of the cars we set up a deal with Loja 5 to be our bearing, axles and wheels supplier and also to help us in the assemble of the car. So, right after the milling of the two cars, we took them to Loja 5 and the owner , Mr. Artur AraĂşjo, polished the cars right away. We had to make some adjustments since the cut from the milling machine was not perfect and damaged a small part of the car next to the rear wheel. In order to solve this we had to give up the straight lines in this part of the car and polish them so as to remove the imperfections from the milling and to have equal cars. Airfoils Afterwards we discussed the details of the rest of the assemble. He had all the equipment we needed to measure the car and make sure we were keeping the same measures on both cars and accord to what was supposed. After polishing the car we assembled the airfoils and we glued them with Premium Tire Glue. Before putting the front airfoils in the right place we had to cut a small piece of wood from the bottom of the car instead of making a whole , as we firstly designed, in which the airfoils would enter, because the amount of wood in the bottom of the whole was way too thin. Bearings The next step was to discussed on how we would assemble the wheels. We decided to go with metallic micro-bearings due to their low weight. We only putted four bearing on the car, since we realized that eight would not improve significantly the rotation of the wheels and would not compensate the extra weight. Wheels We also decided to make our own nylon wheels with the exact measurments we wanted. After the car was painted and ready for the final components, we took it to Loja 5 where the bearings, axles and wheels were waiting to be assembled. Axles To assemble the axles we started by drilling 2 mm wholes on the car and then inserted the axles with pression, as they were 3mm in diameter each. This techenique had to aim to make sure the axles were properly fixed . Problem: In this phase we faced a major problem. When assembling the wheels, after inserting the axles, we noticed that the car was not balanced. The wheels did not touched the ground. Solution: To fix this, we first broadned the front whole, because it was the one causing the troubles, and then ajusted the front axle by covering the remaining space that was not being used with super glue. After this, the car was perfectly balanced and everything was just where it needed to be ! Assembly Finnally, we putted the bearings in the wheels and bonded the wheels with the axles. To conclude the car assembly, we verified again if all four wheels were balanced and touching the ground, if the axles and airfoils were fixed and if there was no other problems in the car. The verification was successful as there were no imperfections, and the car was now ready for the competition !
14
Methods of work Since the beginning we stipulated the words time management and organization in our team. Having in mind we had deadlines and tasks to fulfill, we arrange a way to have everything in one place that all could have access to, something that would allow us to delineate tasks and the time required for them, along with the progress of the same. Thus, we found the podio.com, something that facilitated the work and communication of the team and, later, the manufacture of the portfolio, taking into account that we had all carefully recorded. We also noticed that, when we gather to discuss major issues, such as team identity or planning the stand, we formed organized and concrete ideas in our heads and then communicated to the team while simple ideas, sometimes crazy, but with great potential, were being left without being presented and discussed. With this in mind, before each major topic, we did some brainstorming where we charge all the ideas, no matter how silly they seemed. Although it seems wasted time, at the end, we had one certainty: nothing was left to say, nothing was left to do.
15
Due to the times of recession we are passing through, the amount of ‘’no’’ answers, or even lack of them, when we were searching for sponsors, were multiple. It was time to follow another strategy: ask specifically for the services the companies could offer, so that they could understand that they don’t have to give money, their services are even more important and their help is essential to us. This change really improved the communication among our team and the sponsors and facilitated the marketing work. Facilitated so well that, at this time, we are proud to announce we have all our expenses covered and, luckily, a great relationship with the sponsors. We sent over 70 emails before having our 1st sponsor and had a success rate of just 9 %.
Milling Car Painting Axes Bearings Wheels
Team polos Staff Polos Overall
Pit Display Material
Pit Display Printing Portfolio Printing
‘‘ (...) the resistant trier (...) ‘‘
16
Team Clothing
Facebook Instagram
Team Polo
Team Overall
Website
Staff Polo
By having a unique team clothing we can distinguish and identify ourselves from other teams and visitors. We also had the attention to do some extra polos for our supporters/staff, as our photographer and our teacher. We opted for a silver overall and polo for the team with blue and orange stripes because these are the team official colors. For our supporters we chose a more neutral polo, black, with the aim of not taking attention from the team clothing while also being distinct and show their connection to Mustangs.
Bussiness Cards Through our Facebook page we have reached as much as 17 countries, represented on the map.
Software Used
E-mail us :
f1_in_schools_didaxis@hotmail.com
17
The main aim of our pit display is the combination of the elegance, professional look, and mutual balance with both our team and the portfolio. Keeping these in mind, we tried to create a clean stand that can easily expose our work and development, not containing too much information so that the reading wouldn’t be difficulted. As the new technologies and progress are always associated with the team, we decided to put two tablets: one at the area of manufacturing, playing a video of the whole car manafacturing, since milling to final details, and another, in the area of marketing and sponsors, with the links of all the social networks Mustangs are in. This tablet is interactive so that people can have direct contact to our Facebook account, website and Instagram. All the types of presentation of the team and the work developed have to be cohesive. Because of that, our pit display follows the same line as our portfolio, both in terms of design and info disposal.
18
In the end nothing would have been possible without our sponsors. Not only the ones who offer us their material services but also the ones who gave us their knowledge and current support during this not even half way journey (we hope). Sponsors Strategy COPPER SPONSOR - Logo and facebook account/webpage shared on media; - Logo on portfolio (logo size depends on the sponsorship); - Logo on pit display (logo size depends on the sponsorship). SILVER SPONSOR - All of the above; - Logo on team clothing. GOLD SPONSOR - All of the above; - Logo on every page of the portefolio; - Logo on the car.
GOLD SPONSOR SILVER SPONSOR COPPER SPONSOR
19
General Evaluation In the end of everything: Why F1 in schools? “F1 in Schools is the only global multi-disciplinary challenge in which teams of students aged 9 to 19 deploy CAD/CAM software to collaborate, design, analyze, manufacture, test, and then race miniature compressed air powered balsa wood F1 cars.” Well, why not? Let’s form a team and make a car come to life. Sounds easy, right? Bad news: nothing is what it seems to be! And in the end of everything: Why F1 in schools? At the begging, we wanted more than just a fast car, we wanted a strong team, a team that shined trust, a team with the ability to go further. Here, it comes our team leader and time manager. Having always in mind our capacities and time availabilities, she constructed a work plan based on that, always giving us the freedom to be bold, while controlling our work, and also a huge vote of trust, always putting together the goods of our friendship and letting aside the not so good moments, making focus only on what we had to do. Although a fast car is not the most important, it doesn’t mean it isn’t important at all. So it was time to start working at what fascinated us the most and what brought us to the competition. Together with our design and graphic engineers, days of almost mind crashing, hard work and hours foreseeing the car instead of sleeping, our baby was ready to be milled and get into the little racing world.
A word from each member of the team Rita - Team and Resource Manager I don’t have an answer for ‘Why F1 in Schools ?’ but I do have, all safe, the moments that made us ask that question. All the smiles, tears, discussions, achivments. The moments that make me proud of the team I am managing - and believe me it was not an easy task to do so ! - proud of the things we together achieved and mainly, the moments that make me want to continue here! Pedro - Design Engineer Being the design engineer of the team revealed to be more challenging than I ever expected. I had to do tasks to which I had no previous preparation for and so, this was a whole new learning experience. Although the amount of time I had to spent, the loads of work everyday and the difficulties along the way, I can now say that this project surprised me in an amazing way. I learned so much, things that I would never learn in school, not only educational but also to a personal level. All the responsibilities made me grow as a person and be prepared for the future. Ana - Graphic Designer and Manufacturing Engineer With F1 in Schools I learned much more than what I was expecting ! As the graphic designer I had the chance to develop my knowledge in software such as InDesign and Photoshop. On the other hand, as a Manufacturing Engineer, I had the chance to see the real side of indeed making a car come to life. Sometimes things do not come out as we were expecting, but that did not happen only on the car, it also happened on our team. And still, we are here, we are better persons, we know much more, we are MUSTANGS !
With a team with these values and a car spiked with smiles, tears, good and not so good memories, it was time to show it to the world, time to put all of our efforts together and assemble the car, build a pit display that really exposed what we are and to construct a portfolio, both personal and professional. Through a personal approach and the English language, we could spread our dreams and achievements with the others, giving them space to also contribute with their opinion, as it happened in our Facebook account. In all these days, a simple question remains. In the end of everything: Why F1 in schools? Turning the page of this full and wonderful portfolio, there is a white blank page, ready to be fulfilled. Fulfilled with new expectations, fears, smiles, tears, mottos, …, and mainly, with an answer.
‘‘ (...) and the strong doer ! ‘‘
20