FSAE-A Cars

[andrewd]

im curious to see if anyone attending this years FSAE-A has had time to take photos of their new cars!

if so, please, be my guest, and post away

[andrewd]

im curious to see if anyone attending this years FSAE-A has had time to take photos of their new cars!

if so, please, be my guest, and post away

[Drum]

You aren't assuming we have all finished our cars are you?... http://fsae.com/groupee_common/emoticons/icon_smile.gif

[Colin]

We had our launch last week so i've put a couple of pic's up in the photo gallary

[Amos]

We have our launch tomorrow night and i will post a few pics after that, pending on permission from the rest of the team!

[The guru of guru's]

let me finish the thing before I send pics of it

[andrewd]

nice work colin

mate thats one small diff http://fsae.com/groupee_common/emoticons/icon_wink.gif

oh it looks like you guys will be well placed in that bling bling comp hehe

[Colin]

you don't start a competition you don't think your going to win http://fsae.com/groupee_common/emoticons/icon_wink.gif

[BryanH]

Have seen RO4, not much pimp. more like Kylie Minogue in black body suit.
small IS beautiful

[The guru of guru's]

I thought my mould was complex....you guys at swinnie take the cake!!!!

[Amos]

As promised, i have just posted some pics of our baby from the launch last night in the gallery.....

[Colin]

very nice, looks like we might have some competition for the bling bling comp, i like that rear end. So what does it weigh in at?

[Amos]

Not real sure just yet, few members roughly measured it today. But will have to wait till next week sometime before we get it on scales.

[gug]

i want more people to view our car! click on this link:
Adelaide's gallery (http://fsae.com/eve/forums?a=tpc&s=763607348&f=8356059423&m=54410868711)

post your opinions!

[mike240z]

We have really tried to focus on winning the bling bling competition. Reece is now our permanent polish boy and we even have non-structural carbon contact. http://fsae.com/groupee_common/emoticons/icon_cool.gif I am pretty sure that everyone in the team would like West End Draught if we win, no-one really likes that other SA beer. http://fsae.com/groupee_common/emoticons/icon_biggrin.gif

[andrewd]

good work guys

thats an awesome car

[Chris Boyden]

Nice intake! looks like some cool plastic work
what kind of process did you
guys use to make that? RPM,injection molding??

[Wilso]

Definately a sexy intake and body. Whats up with the wheels, custom? The outer edges look they're spinning...even when sitting still! It looks fast, therefore it must be fast.

[gug]

yeah, the intake is selective laser sintering (SLS). for those who dont know, a ~1mm thick layer of plastic "dust" is scraped across, and a laser shines down and selectively melts it. we didnt get any videos of the process, which sucks, because the part looks amazing as its being made. as you can imagine, you can make basically any shape part you want. really helps when making tiny intakes with complex vanes in them.

the part is made of some sort of nylon plastic. its bloody tough and holds up fine as an intake. cant remember how much it weighs, buts its not heavy compared to our '02 fibreglass and aluminium one.

RPM solutions is the name of the company who did it for us.

wheels are custom made too. 2 piece. 2.5mm thick aluminium rim. our old ones were 2.0mm, but we went and blew them up to 50psi and the rim buckled into a perfect 12 sided shape. what do you guys think of 2.5mm thick rims?

[RaID]

Actually the reason the spinnings are 2.5mm not 2mm is that the 2mm keeps splitting on the dye when spun, the spinner gets only about 1/3 to stay intack,
it was just easier to goto 2.5mm it only adds about 150g extra to the spinning weight

the centres are aluminium CNC turned and milled

[gug]

hmmm, yes... speaking of my innacurate ramblings, that SLS process uses 0.1mm thick layers, not 1mm.

im going back to laa-laa land now, see you all later.

[Snow_fbr]

Just curious as to how many NC hours all these bits and pieces are going to cost you on the cost report. Ever considered casting?

Full boar racing

[Denny Trimble]

Well, a Haas VF-2SS appears to be able to make an upright in about 3 minutes:

Download WMV (http://www.haascnc.com/news/new_files/VF-2SS.wmv)

Yes, we're asking for one this year http://fsae.com/groupee_common/emoticons/icon_smile.gif

[Travis Garrison]

CNC'd parts are stupid cheap if you use proper machining times. Aluminum @ $.75/lb, CNC time at $75 an hour...and like Denny said say 3 minutes for an upright...you start to get the picture. If you use plenty of soft jaws (since they don't get into the cost report) and nest your parts you save on material and time. Besides, casting isn't always a great option for low volume production runs...

The car looks great...What is the final weight?

Travis Garrison
UW FSAE

[Mick_P]

Even though casting is not a great option for low volume, we (luckily) have a great casting supplier who makes low volume components for us. We have access to a rapid-protype machine which is also a good thing http://fsae.com/groupee_common/emoticons/icon_smile.gif
We now have cast Magnesium pedal box, pedals, rear uprights and shifter paddles. Casting also looks awesome on the cost report http://fsae.com/groupee_common/emoticons/icon_razz.gif

If you can, investigate it. It has really helped us this year.

[clausen]

Hi there,

No I guess we didnt really consider casting. What sort of mechanical properties are you getting with (presumably heat treated) castings?

I think next years adelaide team is considering using some of the parts on our car as patterms to cast up something similar.

3 minute uprights? what the hell?

As for our machined parts in our cost report - I havent gotten around to doing them yet.

[Travis Garrison]

Any pics Mick? Sounds like some nice stuff...

-Travis

[John Bucknell]

<BLOCKQUOTE class="ip-ubbcode-quote"><font size="-1">quote:</font><HR>Originally posted by Denny Trimble:
Well, a Haas VF-2SS appears to be able to make an upright in about 3 minutes:

http://www.haascnc.com/news/new_files/VF-2SS.wmv

Yes, we're asking for one this year http://fsae.com/groupee_common/emoticons/icon_smile.gif <HR></BLOCKQUOTE>

Shizzle! That tool changer is insane. Not only that but their program wasted 30-40 seconds deburring. You could pay a freshman 5 bucks and hour to do that.

I want one too.

[Colin]

i've put a couple of pics of our casting in the photo gallary

[clausen]

Geez, that mill is amazing.

Those castings look pretty nice. What is your wheel damper motion ratio? Last years adelaide team struggled with that using a pullrod and very inclined upper wishbones. They were almost parallel.

[reece]

<BLOCKQUOTE class="ip-ubbcode-quote"><font size="-1">quote:</font><HR>Originally posted by mike240z:
We have really tried to focus on winning the bling bling competition. Reece is now our permanent polish boy and we even have non-structural carbon contact. http://fsae.com/groupee_common/emoticons/icon_cool.gif I am pretty sure that everyone in the team would like West End Draught if we win, no-one really likes that other SA beer. http://fsae.com/groupee_common/emoticons/icon_biggrin.gif <HR></BLOCKQUOTE>

???? ok fantastic!@

[Craig.]

What kind of trouble (if any) did you guys have casting magnesium? My impression was it's not the easiest material to work with, expecially casting.

[Snow_fbr]

Casting magnesium isn't that hard, and the foundry we use specialises in this material also which has helped. Mechanical properties vary from foundry to foundry and the best way to figure these out is breaking stuff. As long as you consult with the foundry early in the design process and ensure the material will flow through the mould you shouldn't have any dramas. A few issues we did have early on were porosity and cracking but this can be ironed out by refining your runner/riser placement.

[bigfella]

We did have a teenie problem with magnesium swarf catching fire at one stage when the wheel centres were being tidied up. The guy on the lathe was turning it pretty fast and a bit caught fire and set the rest off that was in the catch tray, so there's a nice black mark in the tray now!

We just fatigue tested our cast rear upright this morning to roughly two seasons worth of racing (20,000 cycles at +/- 7kN), no cracks, no problems.

[jack]

"...its not really an engineering material, its more like cheese"
--Gary Savage, BAR TD on magnesium

http://fsae.com/groupee_common/emoticons/icon_biggrin.gif

[andrewd]

anyone else finished their cars or is it all secret? http://fsae.com/groupee_common/emoticons/icon_wink.gif

[Drum]

We had a successful car launch night last night, there's pics of R04 in the gallery section. I'll get around to posting the herald sun article when I can.

[GTmule]

<BLOCKQUOTE class="ip-ubbcode-quote"><font size="-1">quote:</font><HR>Originally posted by Denny Trimble:
Well, a Haas VF-2SS appears to be able to make an upright in about 3 minutes:

http://www.haascnc.com/news/new_files/VF-2SS.wmv

Yes, we're asking for one this year http://fsae.com/groupee_common/emoticons/icon_smile.gif <HR></BLOCKQUOTE>

Actually, it appears to make two uprights in about 3 minutes (well, mostly, it seems to forget about the other at some point about 3/4 through, but I'd have to watch it again, and it's NOT THAT interesting.) That tool changer is cool, and that facing mill is taking BIG, BIG cuts right at the start....googly.....

[Cement Legs]

<BLOCKQUOTE class="ip-ubbcode-quote"><font size="-1">quote:</font><HR>Originally posted by Colin:
you don't start a competition you don't think your going to win http://fsae.com/groupee_common/emoticons/icon_wink.gif <HR></BLOCKQUOTE>

Why not... the experience is the reason I'm in this. If we finish top 50 I'm happy. http://fsae.com/groupee_common/emoticons/icon_smile.gif

Could you post a couple of pics of these uprights that are made in 90 seconds a piece, minus the freshman deburring time. I'd love to see what that process is producing since we dont have access to a machine nearly that nice.


Cheers

[Denny Trimble]

I don't know if there are pictures, that looks like a "demo part" for a tradeshow or something. Plus, they have twice as many toolchanges as they need just to show off the toolchanger.

They might be doing two sides of the same part, which would make the total cycle time for each part 3 minutes.

[Cement Legs]

HAHAHAHA. I just watched the video. That rocks. I would trade in old family members for one of those http://fsae.com/groupee_common/emoticons/icon_wink.gif. Someone else posted that they were finishing one half of an upright in 3 hrs. I think we can do better than that but not a lot. When you cost something out in your report, do you have to cost out actual times or can you cost out "assuming that we had this tool". hehe

Cheers

[RaID]

Adelaide Uni testing pics up

http://fsae.com/eve/forums?a=albumtopic&s=763607348&topic_oid=30810020911

[you chump]

Magnificent. Car looks really good, with some awesome detailing and integration. Best of luck in the comp.