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Design Guide
Contents
Introduction 4
Creating a New Part in Inventor 5
Saving the Part File 6
Creating Sketches 7
Vertical Reference Plane Guide Sketch 8
Wing and Wheels Guide 10
Wing and Wheels Above Guide 11
Virtual Cargo Guide 12
Virtual Cargo Guide Vertical Reference 13
CO2 Chamber Guide 13
Car Body Side Profile 14
Extrude Side Profile 16
Model Base 17
Extrude Model Base 18
Wheel Hubs 19
Axle Holes 21
CO2 Chamber 22
Closing the Cartridge Hole 23
Rear Wing Mount 24
Front Wing Mount / Tailstock 25
Filleting 26
Tether Line Slot 26
Drilling Axle Holes 28
Create New Assembly 29
Place Part 29
Create Part in Place 30
Axle Bush 31
Pattern and Mirror 32
Wheels 34
Rear Wing 35
Front Wing 40
Tether Line Guide 44
Exporting STL's 45
Axles 46
Calculating Weight of Model 47
Adding Material Properties 50
Adding Decals 51
Drilling Axle Holes CNC Program 52
Introduction
The aim of this guide is to illustrate a way of designing a car to compete in the F1 in Schools
Technology Challenge which complies with the rules and regulations.
The author of this guide works for Denford Ltd and has good knowledge of the machining
process.
The techniques shown in this guide are by no means the only way to create a design, but the
methods have worked well for the author and are offered as a helping hand to get you
started.
This guide uses the 2015 / 2016 Technical regulations and Autodesk Inventor Professional
2016 on Windows 10.
There is also an F1 in Schools Car Manufacturing Design Guide and a QuickCAM Pro
Training Guide available, which will also assist you in the design and manufacture of your
model.
The part files created in this guide are available as a download and can be used as a
reference.
This guide makes use of screen shots, where possible, and will use the following conventions:
Instructions will be in this format
Any software buttons to be pressed, a picture of the button will follow the instruction
This guide assumes that you are using Autodesk Inventor Professional 2016, some features
may be different if using a different version.
Denford Ltd provide Car Manufacturing training and it is recommended that you undertake
the training and use this guide as a revision after completion of the training.
The design in this guide has a weight of 64g according to Inventor. The actual car when
manufactured has a weight of 58g. This discrepancy is likely due to the 3D printed parts
being printed hollow.
This design recorded a time of 1.22 seconds, which would have been fast enough to have
won at 3 of the UK regionals last year.
Good luck!
Creating a New Part in Inventor
To start the design of your model in Inventor you will need to create a new part. You should
create a Standard(mm).ipt
As you will be creating a number of different parts for your design, it is a good idea to create
a folder on your PC where you can save all those parts together.
This will make it easier to locate your components later.
Click the "Inventor" button
You want the X Axis running left to right and the Z Axis
running from bottom to top as the icon next to the view
cube illustrates.
Vertical Reference Plane Guide Sketch
Using the sketch created in the previous step, we are going to create guide lines to ensure
our design meets the regulations.
Starting from the origin (X0,Y0,Z0), draw a horizontal line to the left.
Click to place the line, then press the "ESC" key to end line drawing.
Next we will place a dimension on the line. The Dimension Tool is under the Sketch Tab
grouped under the Constrain Section
Click the "Dimension" button
Dimension is set to 209mm as the Max Overall Length of the car is 210mm as specified in
Critical Regulation T3.3 (6 pts) and I am giving 1mm clearance to avoid a penalty.
I am aiming for maximum length in this design, as the longer an object is the more
aerodynamic it is for the same frontal area.
Next you should draw a rectangle above the existing line. This rectangle will represent the
billet and the previous line is the ground plane.
The rectangle should be 2mm above the Ground Plane as per Regulation T3.6 (6 pts). I
have drawn it 3mm to allow a 1mm safety margin.
The rectangle should be 50mm high as this is the height of the billet.
You should now also draw a rectangle within the billet to represent the cartridge hole. This
should be 19.5mm in height and 60mm long, the centre line should be 29mm from the
bottom of the billet.
Using the "Line", "Rectangle", and "Dimension" buttons.
A line can be converted to a centreline by selecting it and clicking the "Centreline" button.
Convert the centreline of the cartridge hole using the "Centreline" button.
It is a good idea to rename the sketch in order to keep your model organised.
Double click the sketch in the Model Browser and type in the name below:
Wheel Diameter
The smaller a wheel's diameter the less frontal area it will have. Critical Regulation T8.3 (6
pts) states a minimum diameter of 26mm so I will design the wheels to have a 27mm
diameter. This gives a 1mm margin.
Regulation T10.3 (6 pts) states that the wing surface must have a minimum of 3mm clear
space, so we will have 4mm between the front of the wheel and the trailing edge of the wing.
Wings
The longer an object is the more aerodynamic it is. Regulation T10.11 (2 pts) states the
maximum chord length is 25mm so we will make it 24mm.
Regulation T10.12 (2 pts) states the Max thickness of the wing is 6mm. We will make this
5mm.
Regulation T10.12 (2 pts) states the Min thickness of the wing is 1.5mm. We will make this
2.5mm.
Create the sketch shown below and name it Wing and Wheels. It should be created on
the same plane as the Vertical Reference Plane
Wing and Wheels Above Guide
We must now plan the location of the wheels and wings from above.
Wheel Width
The narrower the width of the wheel the less frontal area it will have. Critical Regulation T8.4
(6 pts) states a minimum width of 15mm, so we will make it 16mm.
We are aiming to get the smallest frontal area possible for our design. Critical Regulation
T8.2 (6 pts) states that the distance between opposing wheels must be a minimum of
30mm. We will go 31mm
Wing Span
Regulation T10.9 (6 pts) states that the minimum wing span is 40mm. We will make ours
42mm
Regulation T10.10 states that the minimum span segment is 20mm, ours will be 21mm
Billet Size
The Billet that the car will be machined from is 65mm wide. We should add this dimension
to this sketch.
Create the sketch shown below and name it Wings and Wheels Above. It should be
created on the XY Plane
Virtual Cargo Guide
Virtual Cargo
Critical Regulation T4.3 (6 pts) states that a virtual cargo must be completely encompassed
by the body and be wholly positioned between the front and rear wheel centrelines. This
must also be clearly identified within the engineering drawings Regulation T4.5 (3 pts). We
will make all dimensions for the virtual cargo larger by 2mm as a safety margin to avoid
penalties.
Exclusion Zones
Critical Regulation T4.5 (6 pts) states that no part of the car body must exist in a 15mm
volume immediately rear of the front wheels. The volume is equal to the wheel width and
wheel diameter. We will have a 16mm exclusion zone.
Create the sketch shown below and name it Virtual Cargo. It should be created on the XY
Plane
I have chosen to place the virtual cargo as far back as possible to the exclusion zone in front
of the rear wheels. This will give me more freedom in the shape of the front of the design.
Virtual Cargo Guide Vertical Reference
Virtual Cargo
Critical Regulation T4.3 (6 pts) states that the depth of the virtual cargo should be 8mm
minimum, so we will make ours 10mm to allow a 2mm safety margin.
Exclusion Zone
Critical Regulation T4.5 (6 pts) states that no part of the body of the car must exist in a
15mm volume immediately rear of the front wheels. The volume is equal to the wheel width
and the wheel diameter. We will have a 16mm exclusion zone.
Create the sketch shown below and name it Virtual Cargo Vertical Reference. It should
be created on the XZ Plane
Right click on the Vertical Reference Plane sketch and make it visible
Right click on the Wings and Wheel sketch and make it visible
Right click on the Virtual Cargo Vertical sketch and make it visible
Turning off dimension visibility may make the sketches clearer to view
Using the "Project Geometry" button and then selecting the parts of the sketches you wish
to use as guides for your side profile enables you to then turn off the visibility of the sketches
and makes the sketch view less crowded.
Turn off the visibility of all sketches except the current one.
You may notice in the sketch below that I have ended my profile 2mm in front of the centre
line of the front wheel. I have done this as from this point forward will be my front wing
support and front wing.
Critical Regulation T10.6 (6 pts) states that the whole front wing and any support structure
must be in front of the centre line of the front wheel when viewed in the side elevation.
Starting the wing support 2mm in front of the centre line gives me a 2mm margin.
Click the "Finish Sketch" button when you have finished drawing your profile
Extrude Side Profile
Now that we have sketched our side profile we will want to extrude it.
If you have created a fully closed vector shape in your sketch then it should be selected
automatically.
Create a new sketch, select the base of the side profile extrusion as your sketch plane.
Click the "Project Geometry" button and select the lines that you wish to use.
Turn off visibility of all sketches other than the current one
Extrude Model Base
When you have completed the profile for the model base, exit the sketch.
As we have to attach a decal to the side of the vehicle, as stated in Regulation T4.6 (6 pts)
we should extrude at least 15mm so that the decal fits. We will extrude 16mm.
Wheel Hubs
The wheels will need to be mounted. Next we will create an extrusion that will act as the
wheel hub.
It will be necessary to change the view so that you can see hidden edges as this sketch is
within an extrusion.
Click the "Visual Style" button and select Wireframe with Hidden Edges
If the projected geometry is displayed with solid geometry lines, you may find the sketch
easier to view if you convert the lines to construction lines.
The Wheel Hub is then a circle around the axle centre, which will leave 5mm of material as
the wall thickness after the axle has been drilled. I have done this, as anything under 3mm is
liable to break during machining and I have found 5mm of model board all around to be
strong enough to support the axles.
I have checked clearance between the Wheel Hub and the Model Base to ensure that my
6.35mm cutter will fit between the 2 extrusions. It is important to keep an eye on this and be
aware of the tool that will be used to machine your design from the model board billet.
When you have finished your sketch extrude the Wheel Hubs
You should extrude 31mm, as this is the distance we set between opposing wheels in the
Wing and Wheels sketch
Axle Holes
We are going to use a 6.35mm tool to drill the axle holes in our model.
Use the "Project Geometry" button to select the front, rear, and top of the
CO2 Chamber
Draw a horizontal centre line through the CO2 Chamber and extending beyond it
Click the bottom of the "Plane" button to open the drop down menu.
Draw a rectangle as shown in the image below and trim it so it fits around the Wheel
Hub
Create a sketch on the XZ Plane and find the distance to your axle holes from the datum
For the model we have created the centre line of the axles is 18.5mm down from the datum.
This is Y18.5 in a CNC program.
The rear axle is 25mm from the end of the billet. This is X25 in a CNC program.
The front axle is 167.5mm from the end of the billet. This is X167.5 in a CNC program.
Place Part
We want to place our car body into our new assembly so that we can create the other parts
we need.
Click "Return"
Pattern
Click the "Pattern" button
In the Model Browser, expand the model for the body of your car and then expand the
Origin.
Hopefully, you now have the hang of the Pattern and Mirror tools.
You will be needing them after you have created the Wheel part.
Wheels
We will create the Wheel in much the same way as we created the Axle Bush.
Create a new part named Wheel and use the face of the rear wheel bush as the sketch
plane
Turn on the visibility of the Wing and Wheels sketch in the Model Browser
Draw a circle which is concentric to the wheel geometry and make it 3.1mm in diameter
Exit the sketch and extrude the wheel away from the body by 16mm.
As you can see in the image below, we now have a solid wheel.
Whilst a solid wheel will meet the regulations it is
unlikely to be the fastest. It may be a good idea to
remove some material.
Pattern and Mirror the wheels, as we did with the Axle Bushes
Rear Wing
Now we will design our Rear Wing. This part is to be 3D Printed and as such will be created
as a separate component.
Create a part in place as you have done with the Axle Bush and the Wheel
Name the part Rear Wing and use the face of the rear wing boss as the sketch plane
Turn on visibility of the Wing and Wheels Above sketch in the Model Browser
Create a new sketch on one of the inner faces of the wing span
Use "Project
Geometry"
button to select
the geometry of
that face
Name the part Front Wing and use the top face of the Front Wing Mount as the sketch
plane.
Turn on visibility of the Wing and Wheels sketch in the Model Browser
The profile should extend from the base of your model at the point 1mm back from the front
to 15mm above the base at the point 1mm in front of the Front Wheel Centre Line.
Use "Project Geometry" button to select the geometry of the Front Wing
mount on the Main Body.
Exit sketch and extruded cut the profile towards the front of the car by 15mm
As you can see in the image
to the left, the Front Wing
Mount / Tailstock sticks out
from the end of the Front
Wing.
To make your renderings look better, you can shorten the Tailstock in your model after you
have exported the STL files for machining.
Now that the we have designed the base of our Front Wing, it is time to design the Front
Wing surface.
Create a profile for the Front Wing like the one below
You need to extrude the profile far enough so that you have 2 spans at least 20mm in
length. In the case of this model, the extrusion was 65mm, giving 2 spans of just over 21mm
each.
Don't forget to add 3.175mm fillets to the faces
that mate with the Main Body
The last thing we need to add to the Front Wing is
the Tether Line Slot
Critical Regulation T7.1 (6 pts) states that the car must have 2 guides, one in front of the
Front Axle and one behind the Rear Axle.
Regulation T7.3 (2 pts) states that the minimum distance between the inside edges of the
guides is 120mm.
As you can see below, a sketch has been created on the base of the car to check that the
Tether Line Guides can be fitted to our design within the regulation.
Set units to mm
Resolution is set to Medium by default. This affect the quality of curved surfaces mainly. If set
too low then wheels will be printed as polygons, rather than circles and we do not want this.
Name the part Long Axle and use the right hand side face of the Front Wing as the
sketch plane.
Create a new sketch on the XY Plane
Draw a circle
concentric to the
Rear Wheel which
is 3.2mm in
diameter
Pattern the Long Axle just as you have previously done with the Axle Bushes and Wheels
Calculating Weight of Model
Before manufacturing our car, we may want to know the weight of it.
For the Wings, Wheels and Axle Bushes, the density of the filament is roughly 1g/cm3
The Long Axles are made of steel and have a density of 7.850g/cm3
We can enter this density into Autodesk Inventor to find the weight of our billet when
machined.
We will need to add materials for the Official F1 Model Block and the 3D Printer Material
In the Model Browser, right click on the part and select "Edit"
Right click on the part in the Model Browser again and select "iProperties"
Click "Apply"
Right click on the assembly in the Model Browser (Top of the parts tree)
Select "iProperties"
The Mass of your model will be displayed under the General Properties section.
Adding Decals
To make the renderings of your model look more realistic for your portfolio, you may want to
add decals for your sponsors.
To do this, you first need an image to be used as your decal and it is recommended that you
save these in the same folder as your model.
Decals are placed by first creating a sketch and loading the image for your decal into the
sketch.
Positioning and resizing are all done in the sketch.
After exiting the sketch, the "Decal" button is used to project the image onto the surface.
For curved surfaces, create a workplane above the surface to project the decal onto.
We will place a decal onto the rear wing. You must have the part open, rather than the
assembly for decals.
Type the code below into a new text document and save it as "Axle Holes.fnc"
The values in red should be substituted for the values you recorded on page 28