http://fswiki.us/api.php?action=feedcontributions&feedformat=atom&user=PorterParker 2026-07-26T15:50:02Z User contributions MediaWiki 1.34.1 http://fswiki.us/index.php?title=Machining&diff=3029 2023-09-09T22:47:23Z

<p>PorterParker: /* Grinder */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinders==<br /> Grinder Safety<br /> * Always wear safety glasses.<br /> * Do not remove any safety devices/shields.<br /> * Make sure your sparks are not aimed at anyone.<br /> * Do not use cutting wheels to grind - they WILL explode in your face.<br /> * Do not use abrasive wheels to grind aluminum - it WILL explode in your face.<br /> <br /> [https://en.wikipedia.org/wiki/Rotary_tool Rotary Tools] are also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®]. The rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish. Die grinders are typically more powerful than a rotary tool, but are used simillarly.<br /> <br /> [https://en.wikipedia.org/wiki/Angle_grinder Angle grinders] are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning.<br /> <br /> [https://en.wikipedia.org/wiki/Bench_grinder Bench Grinders] are powerful table mounted grinders. Common wheels include abrasive, wire-wheels, polishing, and deburring. These wheels are long lasting and must be occasionally [https://en.wikipedia.org/wiki/Grinding_dresser dressed]. Have a bench grinder set up for each major alloy you will be using to reduce cross-contamination, keep a small bucket of water on hand for cooling off parts, and make sure the tool rest has a small gap of 2 to 3 mm of the wheel (1⁄16&quot; to 1⁄8&quot;).<br /> <br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic, and also good for very hard or very soft materials. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> something, something, cost report<br /> ===EDM===<br /> [https://en.wikipedia.org/wiki/Electrical_discharge_machining Electric Discharge Machining] works by slowly removing metal between and electrode and the workpiece using electricity. This process is often called &quot;burning&quot;. EDM only works with metallic parts and will not work with most coatings. With the right operator and enough passes, EDM can hold very tight tolerances &lt;±0.025mm (&lt;±0.001).<br /> <br /> While EDMing, material will weld back onto the workpiece. This is called recast and can initiate cracking. Recast must be removed from critical parts. It must also be removed before welding.<br /> ====Wire EDM====<br /> For Wire EDM, a thin wire is used as the electrode. These are good for facing material or making thru-holes (provided there is a pilot hole). Wire EDMs can also cut through very thick material.<br /> ====Sinker EDM====<br /> If the electrode is slowly lowered into the workpiece, it is called sinker EDM. Custom electrodes are machined then used in the EDM to get special shapes. For example, a blind square hole.<br /> ====Hole Popper====<br /> Hole poppers are similar to sinker EDMs but are made specifically for holes. These are ideal for making tiny holes in hardened parts. Probably very uncommon for FSAE.<br /> <br /> ====<br /> <br /> Wire EDM<br /> <br /> <br /> <br /> Sinker EDM====<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3028 2023-09-09T22:44:59Z

<p>PorterParker: </p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> Safety: Always wear safety glasses. Do not remove any safety devices/shields. Make sure your sparks are not aimed at anyone. Do not use cutting wheels to grind - they WILL explode in your face. Do not use abrasive wheels to grind aluminum - it WILL explode in your face.<br /> <br /> [https://en.wikipedia.org/wiki/Rotary_tool Rotary Tools] are also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®]. The rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish. Die grinders are typically more powerful than a rotary tool, but are used simillarly.<br /> <br /> [https://en.wikipedia.org/wiki/Angle_grinder Angle grinders] are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning.<br /> <br /> [https://en.wikipedia.org/wiki/Bench_grinder Bench Grinders] are powerful table mounted grinders. Common wheels include abrasive, wire-wheels, polishing, and deburring. These wheels are long lasting and must be occasionally [https://en.wikipedia.org/wiki/Grinding_dresser dressed]. Have a bench grinder set up for each major alloy you will be using to reduce cross-contamination, keep a small bucket of water on hand for cooling off parts, and make sure the tool rest has a small gap of 2 to 3 mm of the wheel (1⁄16&quot; to 1⁄8&quot;).<br /> <br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic, and also good for very hard or very soft materials. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> something, something, cost report<br /> ===EDM===<br /> [https://en.wikipedia.org/wiki/Electrical_discharge_machining Electric Discharge Machining] works by slowly removing metal between and electrode and the workpiece using electricity. This process is often called &quot;burning&quot;. EDM only works with metallic parts and will not work with most coatings. With the right operator and enough passes, EDM can hold very tight tolerances &lt;±0.025mm (&lt;±0.001).<br /> <br /> While EDMing, material will weld back onto the workpiece. This is called recast and can initiate cracking. Recast must be removed from critical parts. It must also be removed before welding.<br /> ====Wire EDM====<br /> For Wire EDM, a thin wire is used as the electrode. These are good for facing material or making thru-holes (provided there is a pilot hole). Wire EDMs can also cut through very thick material.<br /> ====Sinker EDM====<br /> If the electrode is slowly lowered into the workpiece, it is called sinker EDM. Custom electrodes are machined then used in the EDM to get special shapes. For example, a blind square hole.<br /> ====Hole Popper====<br /> Hole poppers are similar to sinker EDMs but are made specifically for holes. These are ideal for making tiny holes in hardened parts. Probably very uncommon for FSAE.<br /> <br /> ====<br /> <br /> Wire EDM<br /> <br /> <br /> <br /> Sinker EDM====<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3023 2023-07-15T17:29:13Z

<p>PorterParker: /* Cutting */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic, and also good for very hard or very soft materials. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> something, something, cost report<br /> ===EDM===<br /> [https://en.wikipedia.org/wiki/Electrical_discharge_machining Electric Discharge Machining] works by slowly removing metal between and electrode and the workpiece using electricity. This process is often called &quot;burning&quot;. EDM only works with metallic parts and will not work with most coatings. With the right operator and enough passes, EDM can hold very tight tolerances &lt;±0.025mm (&lt;±0.001).<br /> <br /> While EDMing, material will weld back onto the workpiece. This is called recast and can initiate cracking. Recast must be removed from critical parts. It must also be removed before welding.<br /> ====Wire EDM====<br /> For Wire EDM, a thin wire is used as the electrode. These are good for facing material or making thru-holes (provided there is a pilot hole). Wire EDMs can also cut through very thick material.<br /> ====Sinker EDM====<br /> If the electrode is slowly lowered into the workpiece, it is called sinker EDM. Custom electrodes are machined then used in the EDM to get special shapes. For example, a blind square hole.<br /> ====Hole Popper====<br /> Hole poppers are similar to sinker EDMs but are made specifically for holes. These are ideal for making tiny holes in hardened parts. Probably very uncommon for FSAE.<br /> <br /> ====<br /> <br /> Wire EDM<br /> <br /> <br /> <br /> Sinker EDM====<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3022 2023-07-15T16:57:37Z

<p>PorterParker: /* Cutting? */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting&lt;span&gt;is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> <br /> something, something, cost report<br /> ===EDM===<br /> Electric Discharge Machining works by slowly removing metal between and electrode and the workpiece using electricity. This process is often called &quot;burning&quot;.<br /> ====<br /> <br /> Wire EDM<br /> <br /> <br /> <br /> Sinker EDM====<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3021 2023-07-15T16:54:28Z

<p>PorterParker: /* Cutting? */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting&lt;span&gt;is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> <br /> <br /> something, something, cost report<br /> ===EDM===<br /> [https://en.wikipedia.org/wiki/Electrical discharge_machining Electric Discharge Machining]<br /> <br /> <br /> works by slowly removing metal between and electrode and the workpiece using electricity. This process is often called &quot;burning&quot;.<br /> <br /> Wire EDM<br /> <br /> <br /> <br /> Sinker EDM<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3020 2023-07-15T16:48:55Z

<p>PorterParker: /* Water Jetting */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting&lt;span&gt;is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> <br /> <br /> something, something, cost report<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=3019 2023-07-15T16:48:37Z

<p>PorterParker: /* Water Jetting */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> <br /> <br /> Health and safety in the workshop environment and on track is a crucial priority for Formula Student teams and must be treated as such. If significant injury or death occurs related to work in a Formula Student team, there will be a risk of the university or faculty (governing body) to shut down the team permanently. Safety is not to be underestimated and a set of workplace safety policies never guarantees personal safety unless practiced. Lead members, or designated HSE responsible members should be proactive in making internal guidelines for PPE inventory, changing respiratory filters in masks etc. All members have a personal responsibility to follow safety guidelines set forth by the university and the team itself. HSE policies should reflect the principle of [https://en.wikipedia.org/wiki/ALARP ALARP] .<br /> ===Personal Protective Equipment (PPE)===<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> <br /> Safety goggles are most common to use for any workshop activities. Goggles should be worn for most activities, primarily when working with moving machinery, or labor that can have projectiles/ dust going into eyes.<br /> <br /> <br /> Hearing protection such as ear muffs or ear plugs are highly useful for loud activities. It should be noted that hearing protection is useful for impulse noises (i.e hammering) and for constant loud noises over long periods of time, like machine humming under operation. Both types of noises can accelerate noise-induced hearing loss.<br /> <br /> <br /> <br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''''''<br /> <br /> <br /> ''''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> A drill press is not a vertical mill. They may look similar but (1) a mill is designed to take side loads and (2) mills can usually place the head of the machine more precisely.<br /> <br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> Water Jet cutting&lt;span&gt;is performed by a high pressure jet of water containing an abrasive grit.&lt;/span&gt;Therefore, it is usually higher quality than laser or plasma because it doesn't use heat and won't warp the part. The workpiece can also be non-metallic such as carbon fiber or plastic. Water Jet can hold good ~±0.1mm (~±0.005&quot;) tolerances depending on the machine used. Before welding a water jet part, the surface needs to be prepared more than usual to remove abrasive imbedded in the surface. Quotes for water jet jobs are very budget friendly and have a faster turn around time than conventional machining.<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> something, something, cost report<br /> <br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> With 2.5 axis machining, you have fine control in the x and y axes but rudimentary control in the z axis. 2.5 axis mills are simpler and cheaper, while still being able to manufacture many parts.<br /> <br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Chain_Drive&diff=1756 2020-06-05T22:03:55Z

<p>PorterParker: /* Sprockets */</p> <hr /> <div>A chain and sprocket [[Drivetrain|drive system]] requires lubrication and a [[tensioner|tensioner]].<br /> ==Chains==<br /> explain motorcycle chain sizes, ratings.<br /> <br /> Chains can be easily lengthened or shortened using quick release links.<br /> ===Sealed chain===<br /> Sealed chains use o-rings to seal in a lubricant, great for daily driving. Also used in racing applications. Very common in motorcycle shops.<br /> ===Non-Sealed chain===<br /> Non-sealed requires more frequent lubrication application and are commonly used for motocross or low mileage applications.<br /> ==Sprockets==<br /> Sprockets are made of [[Steel|steel]], [[Aluminum|aluminum]], or [[Titanium|titanium]] and can replaced to change the [[Drivetrain#Final_Drive_Ratio|final drive ratio]]. Sprockets can be bought or easily made by [[Machining#Laser Cutting|laser-cutting]], [[Machining#Water Jetting|water-jetting]], or [[Machining#CNC Machining|CNC machining]].<br /> <br /> As the number of teeth decrease, the sprocket will approach a polygon instead of a circle. This is called the polygon effect or chordal action and results in a variation in speed output (Imagine driving on square wheels).&lt;ref&gt;[http://chain-guide.com/basics/2-2-1-chordal-action.html http://chain-guide.com/basics/2-2-1-chordal-action.html]&lt;/ref&gt; Typical sprockets don't ever go under 11 or 12 teeth for 35 and 40-series chains.<br /> <br /> ==Drivetrain Shield==<br /> Chain drives have specific shielding rules in FSAE covered in T.5.2.7 (link to rules) (what about FS?).<br /> ==Failure Modes==<br /> If there is excessive sprocket wear, improper chain [[Tensioner|tension]], improperly installed quick release, no lubricant, or if the chain drive is not in the same plane there WILL be a failure. Chain failures can be extremely dangerous for both the vehicle and nearby people. (more on failure modes/design flaws?)&lt;br /&gt;&lt;br /&gt;+No slip possible in chain drive without failure [https://www.myodesie.com/wiki/index/returnEntry/id/3058#Chain%20Drive%20Advantages https://www.myodesie.com/wiki/index/returnEntry/id/3058#Chain%20Drive%20Advantages]<br /> ==References==<br /> &lt;references /&gt;<br /> <br /> [[Category:Internal Combustion]][[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Drivetrain&diff=1755 2020-06-05T22:02:26Z

<p>PorterParker: </p> <hr /> <div>A system is needed to transfer mechanical energy from the [[engine|engine]] to the ground. The train takes the rotational mechanical energy from the engine and transfers it to the [[wheels|wheels]]. <br /> =Gearing=<br /> <br /> * Geometric gearing<br /> ** phi - i_(n-1)/(i_n) &lt;= n_(max)/n_(T_max)<br /> * progressive<br /> ** phi_G = phi_G1 * phi_G2<br /> *** G1 and G2 are predefined constants<br /> ** i_(z-1) = i_(z) * phi_G1<br /> *** bruh moment, will likely just move to own page for full expl.<br /> ** CBR600RR is progressive<br /> Gearing determines crawl speed, top speed and torque availability at any vehicle speed in between.<br /> <br /> Need to also be mindful of how much tractive force you will be generating in any given gear. This plays with tire selection and helps determine what happens when the driver firewalls the go pedal.<br /> <br /> This also plays into forces on the differential and driveline components.<br /> ==Motorcycle Gearboxes==<br /> Motorcycle engines have internal sequential gearboxes. This is means that the gearing is located inside the crankcase. The oiling is managed by the engine's oil system. Typically these are 5 (YZ450) or 6 speeds (CBR600RR). Drivetrain efficiency for a geared system is close to 98% [citation needed].<br /> ===Clutch===<br /> Most motorcycles use a wet plate clutch pack whereas most cars use a single dry plate clutch. Wet plate clutch packs are immersed in oil (wet) and use multiple friction plates (pack).<br /> <br /> <br /> The motorcycle clutch uses a set of linear springs or a diaphram (less common). When engaged, the springs squeeze a series of clutch plates tight enough to restrict relative rotation. This mechanically links the engine output to the crankshaft. When disengaged, the plates are under no pressure and have the ability to rotate freely relative to one another. This allows the engine to spin without outputting a torque. &lt;br /&gt;[we should get a simple diagram of how the torque flows through the engine here]<br /> <br /> <br /> Talk about slipper clutches<br /> ==Continuously Variable Transmissions==<br /> These allow for an infinite combination of engine to wheel speeds. The benefits of this include allowing the engine to be run at peak power, peak efficiency, or peak torque at any vehicle speeds. The downsides are lower efficiency (around 70-80% efficiency [citation needed] and a lower peak torque transfer.<br /> ==Gear Selection==<br /> {{Main|Shifter}}Not sure if we need a separate section now that it has its own page, can probably just link in gearbox discussion -simon<br /> =Drive Mechanisms=<br /> There are two ways to get power from the engine to the tires: place the engine output on the same axis as the wheel(s) being driven (direct drive) or transmit the power from the engine to a parallel driven axis connected to the wheels (indirect drive). For combustion vehicles, indirect drives are the prevalent design as it allows for a flexibility of engine placement relative to wheels, a greater degree of drive ratios, and it often easier to implement. [citation or explanation needed]<br /> ==Indirect Drive==<br /> ===Chain Drive===<br /> {{Main|Chain Drive}}Power transmission using a chain drive uses a drive sprocket on the engine connected by a chain to a driven sprocket on the rear axle(s). A chain drive is the most common system found in FS [citation needed?] for a few reasons: most motorcycles already use this system, and it is easy to convert the existing system to drive a formula car, the system is robust, and the minimum design work to implement a functional system is limited [explanation or citation needed] (explanation - low part count, oem sprockets available, no pretension, no slip, wide margin of error for design flaws except planar misalignment).<br /> <br /> moved most info to own page - i think it'll allow us a deeper discussion without overwhelming this page -simon<br /> ===Belt Drive===<br /> Power can also be transmitted with a belt and two pulleys. A belt and pulley does not require lubrication, but still needs a [[tensioner|tensioner]] (also needs to be pretensioned or else you'll get big slip). Pulleys are more expensive than sprockets [citation needed] and can be difficult to manufacture for most teams [citation or explanation needed, is it hard to design but easy to manufacture or both or easy to design but hard to manufacture?]. The chordal action is less apparent on belt drives because the pulley is more circular than a sprocket.&lt;br /&gt;-system allows slip<br /> ===CVT===<br /> can be done w belt or laminated chain(which could be argued to just be a belt)<br /> ===Driveshaft===<br /> ===Gear Drive===<br /> ==Direct Drive==<br /> ==Drivetrain Shield==<br /> =Final Drive Ratio=<br /> The final drive ratio (FDR) is the gearing reduction between the transmission output shaft and the differential. Changing the FDR to a smaller ratio will result in a lower top speed, close gearing, and higher acceleration. A larger ratio will result in a higher top speed, wide gearing, and lower acceleration. Talk about how to choose FDR - impact on number of shifts, acceleration, packaging, integrate w stock gearbox if not running all 5 or 6 stock gears (some teams only run with 3 or 4).<br /> =Traction Model=<br /> what it looks like, what it means (wheel spin, FDR is high or low, top speed, shift points), how to draw(excel, optimumL).<br /> <br /> =Differentials=<br /> {{main|Differential}}<br /> =Driveshafts=<br /> <br /> * CV Joints<br /> ** tripods<br /> ** those rubber shits<br /> ** others<br /> * flex plates<br /> * Half-shafts<br /> ** material<br /> ** how to safely change the length and heat-treat the HAZ<br /> * lateral play<br /> * splines<br /> ** should be outside the major shaft diameter<br /> ** circlip grooves/failures<br /> * Torque Steer baby - probably make another page for this for details on concept and derivation<br /> <br /> =Hubs=<br /> {{main|Hubs}}<br /> The driveshaft sends power to the wheel hub. The hub is held within the upright/knuckle with wheel bearings. Hubs can be lug/stud-centric, hub-centric, or center-lock.<br /> =Wheels=<br /> {{main|Wheels}}<br /> <br /> =Validation=<br /> In vehicle simulations, including driveline affects become important the more detailed the vehicle model gets. The brake torque and horsepower are not what is seen by the tire's contact patch. A physical measurement of driveline forces should be undertaken at some point. It is not likely needed to do this every year however it should be done at least once to correlate model to reality. <br /> <br /> This is typically a rotating measurement and typically involves the use of strain gauges. Wireless amplifiers are often needed. Several companies make them available such as Texense, Izze Racing and Lord Microstrain.<br /> <br /> --Can talk more about the measurement in the electronics section. Maybe keep this higher level? You could right a whole section just on measurement techniques, uncertainty analysis, error influence coefficients.I think it is worth calling out a couple companies so teams at least have some direction. In the case of wireless strain gauge amps you can go down a real rabbit hole and not find what you need. As far as the gauge install itself, I think that is a lot easier to self research.<br /> <br /> =References=<br /> &lt;references /&gt;<br /> <br /> [[Category:Internal Combustion]][[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Differential&diff=1754 2020-06-05T21:50:56Z

<p>PorterParker: /* Further Reading */</p> <hr /> <div>A differential is a mechanism that allows the two driven wheels to rotate at different speeds to assist in cornering.<br /> =Function=<br /> When turning a corner, the outer wheels will follow a path with a greater radius of curvature. This difference in radius means the outside wheels will have to travel a longer distance, and rotate faster than the inside wheels.in a rear wheel drive car, the front two wheels are allowed to rotate at a different rate, so this does not pose a problem. The rear wheels, however, both have to be driven by the engine, and therefore are mechanically connected to each other, so there is no freedom of movement between them inherent in the design.<br /> <br /> [need a pic of cornering to demonstrate wheel travel difference]{{#evt:service=youtube|id=https://www.youtube.com/watch?v=yYAw79386WI}}<br /> =Types=<br /> ==Open Differential==<br /> An open differential is a gear assembly that allows the two rear wheels to spin independently of each other, while maintaining the average rotational speed. If the outside wheel spins faster than it would without the differential, the inside wheel must spin and equivalent amount slower. Similarly, the torque transferred to the ground, but is split in varying amounts between the two rear wheels depending on their relative velocities. The faster spinning wheel will see a proportionally greater amount of torque from the engine.<br /> <br /> This torque differential between the two wheels can become problematic in high torque applications where the torque is desired to go to the wheel with the greatest amount of traction, not the greatest rotational velocity, such as corner exit, or corner entry if using an inboard brake. To solve this problem, a differential that can limit the amount of slip is desired.<br /> ==Limited Slip Differential==<br /> A limited slip differential (LSD) allows the two wheels to rotate at different speeds, but is limited to a maximum difference. The maximum limit of torque sent to one side is the torque bias ratio (TBR) of the LSD.<br /> ===Clutch===<br /> 2-Way, 1-Way, 1.5-Way<br /> ===Geared===<br /> Geared LSDs are sometimes referred to by the supplier: Torsen, Quaife, and Eaton. Greared LSDs rely on the geometry of gears to determine the TBR.<br /> <br /> Torsen makes three versions. The T-1 uses cross axis planetary helical and spurr gears. The T-2 uses axial planetary helical gears. The T-3 is designed as a center differential for AWD OEM applications.<br /> ===Locking===<br /> ====Detroit Locker====<br /> ====Cam and Pawl====<br /> ===Viscous===<br /> Uses hydraulics to differentiate speeds. Not used in Formula?<br /> ==Spool==<br /> Although not technically a differential, a spool does still transfer power from the engine to the wheels. A spool mechanically ties the two wheels together: they will always spin at the same speed. This can lead to massive understeer unless suspension is designed to compensate. The only main advantage to using a spool is the weight savings.<br /> ==Electronic Differential==<br /> It is fairly common to find electric formulas where the [[battery pack]] powers more than one motor on each side of the car. These two motors are then controlled individually and behave like if a virtual electronic differential was separating each other.<br /> <br /> not sure if anyone uses eLSDs but they're common in industry, dont know if this is the right section or the LSD section is better<br /> <br /> =Differentials used in Formula=<br /> {| class=&quot;wikitable&quot;<br /> |-<br /> |Name<br /> |Type<br /> |TBR<br /> |Comments<br /> |-<br /> |[https://torsen.com/fsae/ Torsen University Special]<br /> |T-1 or T-2 Torsen LSD<br /> |2.6:1<br /> |obsolete<br /> |-<br /> |TRE mk1<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |obsolete<br /> |-<br /> |[https://www.taylor-race.com/catalog/1283 TRE mk2]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |[https://shop.drexler-motorsport.com/en/limited-slip-differential/formula-student/ Drexler]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |}<br /> =Further Reading=<br /> * https://www.taylor-race.com/sites/default/files/DIFFERENTIAL%20ESSAY%20W%20PHOTOS2.pdf<br /> * [https://www.youtube.com/playlist?list=PL2ir4svMoaYim-RSNWEh-aIfdcM6plSly Engineering Explained:Differentials (Youtube Playlist)]<br /> * https://www.awdwiki.com/en/torsen/<br /> <br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;[[Category:Internal Combustion]]<br /> [[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Differential&diff=1753 2020-06-05T21:49:58Z

<p>PorterParker: /* Types */</p> <hr /> <div>A differential is a mechanism that allows the two driven wheels to rotate at different speeds to assist in cornering.<br /> =Function=<br /> When turning a corner, the outer wheels will follow a path with a greater radius of curvature. This difference in radius means the outside wheels will have to travel a longer distance, and rotate faster than the inside wheels.in a rear wheel drive car, the front two wheels are allowed to rotate at a different rate, so this does not pose a problem. The rear wheels, however, both have to be driven by the engine, and therefore are mechanically connected to each other, so there is no freedom of movement between them inherent in the design.<br /> <br /> [need a pic of cornering to demonstrate wheel travel difference]{{#evt:service=youtube|id=https://www.youtube.com/watch?v=yYAw79386WI}}<br /> =Types=<br /> ==Open Differential==<br /> An open differential is a gear assembly that allows the two rear wheels to spin independently of each other, while maintaining the average rotational speed. If the outside wheel spins faster than it would without the differential, the inside wheel must spin and equivalent amount slower. Similarly, the torque transferred to the ground, but is split in varying amounts between the two rear wheels depending on their relative velocities. The faster spinning wheel will see a proportionally greater amount of torque from the engine.<br /> <br /> This torque differential between the two wheels can become problematic in high torque applications where the torque is desired to go to the wheel with the greatest amount of traction, not the greatest rotational velocity, such as corner exit, or corner entry if using an inboard brake. To solve this problem, a differential that can limit the amount of slip is desired.<br /> ==Limited Slip Differential==<br /> A limited slip differential (LSD) allows the two wheels to rotate at different speeds, but is limited to a maximum difference. The maximum limit of torque sent to one side is the torque bias ratio (TBR) of the LSD.<br /> ===Clutch===<br /> 2-Way, 1-Way, 1.5-Way<br /> ===Geared===<br /> Geared LSDs are sometimes referred to by the supplier: Torsen, Quaife, and Eaton. Greared LSDs rely on the geometry of gears to determine the TBR.<br /> <br /> Torsen makes three versions. The T-1 uses cross axis planetary helical and spurr gears. The T-2 uses axial planetary helical gears. The T-3 is designed as a center differential for AWD OEM applications.<br /> ===Locking===<br /> ====Detroit Locker====<br /> ====Cam and Pawl====<br /> ===Viscous===<br /> Uses hydraulics to differentiate speeds. Not used in Formula?<br /> ==Spool==<br /> Although not technically a differential, a spool does still transfer power from the engine to the wheels. A spool mechanically ties the two wheels together: they will always spin at the same speed. This can lead to massive understeer unless suspension is designed to compensate. The only main advantage to using a spool is the weight savings.<br /> ==Electronic Differential==<br /> It is fairly common to find electric formulas where the [[battery pack]] powers more than one motor on each side of the car. These two motors are then controlled individually and behave like if a virtual electronic differential was separating each other.<br /> <br /> not sure if anyone uses eLSDs but they're common in industry, dont know if this is the right section or the LSD section is better<br /> <br /> =Differentials used in Formula=<br /> {| class=&quot;wikitable&quot;<br /> |-<br /> |Name<br /> |Type<br /> |TBR<br /> |Comments<br /> |-<br /> |[https://torsen.com/fsae/ Torsen University Special]<br /> |T-1 or T-2 Torsen LSD<br /> |2.6:1<br /> |obsolete<br /> |-<br /> |TRE mk1<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |obsolete<br /> |-<br /> |[https://www.taylor-race.com/catalog/1283 TRE mk2]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |[https://shop.drexler-motorsport.com/en/limited-slip-differential/formula-student/ Drexler]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |}<br /> =Further Reading=<br /> * https://www.taylor-race.com/sites/default/files/DIFFERENTIAL%20ESSAY%20W%20PHOTOS2.pdf<br /> * [https://www.youtube.com/playlist?list=PL2ir4svMoaYim-RSNWEh-aIfdcM6plSly Engineering Explained:Differentials (Youtube Playlist)]<br /> <br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;[[Category:Internal Combustion]]<br /> [[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Differential&diff=1752 2020-06-04T22:09:24Z

<p>PorterParker: </p> <hr /> <div>A differential is a mechanism that allows the two driven wheels to rotate at different speeds to assist in cornering.<br /> =Function=<br /> When turning a corner, the outer wheels will follow a path with a greater radius of curvature. This difference in radius means the outside wheels will have to travel a longer distance, and rotate faster than the inside wheels.in a rear wheel drive car, the front two wheels are allowed to rotate at a different rate, so this does not pose a problem. The rear wheels, however, both have to be driven by the engine, and therefore are mechanically connected to each other, so there is no freedom of movement between them inherent in the design.<br /> <br /> [need a pic of cornering to demonstrate wheel travel difference]{{#evt:service=youtube|id=https://www.youtube.com/watch?v=yYAw79386WI}}<br /> =Types=<br /> ==Open Differential==<br /> An open differential is a gear assembly that allows the two rear wheels to spin independently of each other, while maintaining the average rotational speed. If the outside wheel spins faster than it would without the differential, the inside wheel must spin and equivalent amount slower. Similarly, the torque transferred to the ground, but is split in varying amounts between the two rear wheels depending on their relative velocities. The faster spinning wheel will see a proportionally greater amount of torque from the engine.<br /> <br /> This torque differential between the two wheels can become problematic in high torque applications where the torque is desired to go to the wheel with the greatest amount of traction, not the greatest rotational velocity, such as corner exit, or corner entry if using an inboard brake. To solve this problem, a differential that can limit the amount of slip is desired.<br /> ==Limited Slip Differential==<br /> A limited slip differential (LSD) allows the two wheels to rotate at different speeds, but is limited to a maximum difference. The maximum limit is the torque bias ratio (TBR) of the LSD.<br /> ===Clutch===<br /> ===2-Way, 1-Way, 1.5-Way===<br /> ===Geared===<br /> ====Helical (Torsen/Quaife)====<br /> ===Locking===<br /> ====Detroit Locker====<br /> ====Cam and Pawl====<br /> ===Viscous===<br /> ==Spool==<br /> not really a kind of differential, just a way to lock the half shafts together<br /> ==Electronic Differential==<br /> It is fairly common to find electric formulas where the [[battery pack]] powers more than one motor on each side of the car. These two motors are then controlled individually and behave like if a virtual electronic differential was separating each other.<br /> <br /> not sure if anyone uses eLSDs but they're common in industry, dont know if this is the right section or the LSD section is better<br /> =Differentials used in Formula=<br /> {| class=&quot;wikitable&quot;<br /> |-<br /> |Name<br /> |Type<br /> |TBR<br /> |Comments<br /> |-<br /> |[https://torsen.com/fsae/ Torsen University Special]<br /> |T-1 or T-2 Torsen LSD<br /> |2.6:1<br /> |obsolete<br /> |-<br /> |TRE mk1<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |obsolete<br /> |-<br /> |[https://www.taylor-race.com/catalog/1283 TRE mk2]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |[https://shop.drexler-motorsport.com/en/limited-slip-differential/formula-student/ Drexler]<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |}<br /> =Further Reading=<br /> * https://www.taylor-race.com/sites/default/files/DIFFERENTIAL%20ESSAY%20W%20PHOTOS2.pdf<br /> * [https://www.youtube.com/playlist?list=PL2ir4svMoaYim-RSNWEh-aIfdcM6plSly Engineering Explained:Differentials (Youtube Playlist)]<br /> <br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;[[Category:Internal Combustion]]<br /> [[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Differential&diff=1751 2020-06-04T22:00:55Z

<p>PorterParker: </p> <hr /> <div>A differential is a mechanism that allows the two driven wheels to rotate at different speeds to assist in cornering.<br /> =Function=<br /> When turning a corner, the outer wheels will follow a path with a greater radius of curvature. This difference in radius means the outside wheels will have to travel a longer distance, and rotate faster than the inside wheels.in a rear wheel drive car, the front two wheels are allowed to rotate at a different rate, so this does not pose a problem. The rear wheels, however, both have to be driven by the engine, and therefore are mechanically connected to each other, so there is no freedom of movement between them inherent in the design.<br /> <br /> [need a pic of cornering to demonstrate wheel travel difference]{{#evt:service=youtube|id=https://www.youtube.com/watch?v=yYAw79386WI}}<br /> =Types=<br /> ==Open Differential==<br /> An open differential is a gear assembly that allows the two rear wheels to spin independently of each other, while maintaining the average rotational speed. If the outside wheel spins faster than it would without the differential, the inside wheel must spin and equivalent amount slower. Similarly, the torque transferred to the ground, but is split in varying amounts between the two rear wheels depending on their relative velocities. The faster spinning wheel will see a proportionally greater amount of torque from the engine.<br /> <br /> This torque differential between the two wheels can become problematic in high torque applications where the torque is desired to go to the wheel with the greatest amount of traction, not the greatest rotational velocity, such as corner exit, or corner entry if using an inboard brake. To solve this problem, a differential that can limit the amount of slip is desired.<br /> ==Limited Slip Differential==<br /> A limited slip differential (LSD) allows the two wheels to rotate at different speeds, but is limited to a maximum difference. The maximum limit is the torque bias ratio (TBR) of the LSD.<br /> ===Clutch===<br /> ===2-Way, 1-Way, 1.5-Way===<br /> ===Geared===<br /> ====Helical (Torsen/Quaife)====<br /> ===Locking===<br /> ====Detroit Locker====<br /> ====Cam and Pawl====<br /> ===Viscous===<br /> ==Spool==<br /> not really a kind of differential, just a way to lock the half shafts together<br /> ==Electronic Differential==<br /> It is fairly common to find electric formulas where the [[battery pack]] powers more than one motor on each side of the car. These two motors are then controlled individually and behave like if a virtual electronic differential was separating each other.<br /> <br /> not sure if anyone uses eLSDs but they're common in industry, dont know if this is the right section or the LSD section is better<br /> =Differentials used in Formula=<br /> <br /> {| class=&quot;wikitable&quot;<br /> |-<br /> |Name<br /> |Type<br /> |Comments<br /> |-<br /> |Torsen University Special<br /> |T-1 or T-2 Torsen LSD<br /> |obsolete. TBR 2.6:1<br /> |-<br /> |TRE mk1<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |TRE mk2<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |Drexler<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |&lt;br /&gt;<br /> |}<br /> <br /> <br /> =Further Reading=<br /> <br /> * https://www.taylor-race.com/sites/default/files/DIFFERENTIAL%20ESSAY%20W%20PHOTOS2.pdf<br /> <br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;[[Category:Internal Combustion]]<br /> [[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Differential&diff=1750 2020-06-04T21:52:32Z

<p>PorterParker: </p> <hr /> <div>A differential is a mechanism that allows the two driven wheels to rotate at different speeds to assist in cornering.<br /> =Function=<br /> When turning a corner, the outer wheels will follow a path with a greater radius of curvature. This difference in radius means the outside wheels will have to travel a longer distance, and rotate faster than the inside wheels.in a rear wheel drive car, the front two wheels are allowed to rotate at a different rate, so this does not pose a problem. The rear wheels, however, both have to be driven by the engine, and therefore are mechanically connected to each other, so there is no freedom of movement between them inherent in the design.<br /> <br /> [need a pic of cornering to demonstrate wheel travel difference]<br /> {{#evt:service=youtube|id=https://www.youtube.com/watch?v=yYAw79386WI}}<br /> =Types=<br /> ==Open Differential==<br /> An open differential is a gear assembly that allows the two rear wheels to spin independently of each other, while maintaining the average rotational speed. If the outside wheel spins faster than it would without the differential, the inside wheel must spin and equivalent amount slower. Similarly, the torque transferred to the ground, but is split in varying amounts between the two rear wheels depending on their relative velocities. The faster spinning wheel will see a proportionally greater amount of torque from the engine.<br /> <br /> This torque differential between the two wheels can become problematic in high torque applications where the torque is desired to go to the wheel with the greatest amount of traction, not the greatest rotational velocity, such as corner exit, or corner entry if using an inboard brake. To solve this problem, a differential that can limit the amount of slip is desired.<br /> <br /> ==Limited Slip Differential==<br /> A limited slip differential (LSD) allows the two wheels to rotate at different speeds, but is limited to a maximum difference. The maximum limit is the ratio of the LSD.<br /> ===Clutch===<br /> ===2-Way, 1-Way, 1.5-Way===<br /> ===Geared===<br /> ====Torsen====<br /> ===Locking===<br /> ====Detroit Locker====<br /> ====Cam and Pawl====<br /> ===Viscous===<br /> ==Spool==<br /> not really a kind of differential, just a way to lock the half shafts together<br /> <br /> ==Electronic Differential==<br /> &lt;span&gt;It is fairly common to find electric formulas where the [[battery pack]] powers more than one motor on each side of the car. These two motors are then controlled individually and behave like if a virtual electronic differential was separating each other.&lt;/span&gt;<br /> <br /> not sure if anyone uses eLSDs but they're common in industry, dont know if this is the right section or the LSD section is better<br /> =Differentials used in Formula=<br /> Torsen University Special<br /> TRE MK1<br /> TRE MK2<br /> Drexler<br /> =Further Reading=<br /> * https://www.taylor-race.com/sites/default/files/DIFFERENTIAL%20ESSAY%20W%20PHOTOS2.pdf<br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;<br /> [[Category:Internal Combustion]]<br /> [[Category:Electric Vehicle]]</div>

PorterParker http://fswiki.us/index.php?title=Drill_bits&diff=1749 2020-06-04T21:27:05Z

<p>PorterParker: </p> <hr /> <div>A short overview of drill bits and their types<br /> ==Varieties==<br /> ===Twist drill===<br /> ===Step drill===<br /> ===Hole saw===<br /> ===Center drill===<br /> ===Core drill===<br /> ===Countersink bit===<br /> ===Spade drill===<br /> ===Masonry drill===<br /> ==Alloy==<br /> ===Steel===<br /> Terrible<br /> ===HSS===<br /> This is the benchmark material for drill bits.<br /> ===Cobalt steel===<br /> Better heat, wear, and lifetime than HSS. <br /> ===Carbide===<br /> Harder and stronger, but expensive and brittle.<br /> ==Coating==<br /> Coatings affect price, corrosion resistance, lifetime, hardness, heat, and chip evacuation.<br /> ===Black oxide===<br /> Inexpensive coating that increases corrosion resistance and life.<br /> ===Titanium===<br /> Multiple types of titanium based coatings exist. They are superior to black oxide but more costly.<br /> <br /> [[Category:Manufacturing_Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1748 2020-06-04T21:16:00Z

<p>PorterParker: /* Drill */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1747 2020-06-04T20:58:37Z

<p>PorterParker: /* Drill */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> Drills use [[drill_bits]] to remove material and create a hole. Other attachments can be installed such as: burs, sanders, grinders, and polishing wheels.<br /> ===Hand Drill===<br /> Hand drills are portable and can be corded or battery powered. The RPM is controlled by the trigger pull and sometimes uses a gearbox; feed rate is controlled by the pressure applied. Straight holes are more difficult to achieve with hand drills, and it is recommended to use a center punch to reduce walking.<br /> ===Drill Press===<br /> Drill presses are more stable than hand drills. They have a movable table to attach a [[Machining#presses#vice|vice]] and a spindle with a chuck. The RPM is typically controlled by a gearbox and sometimes with a VFD; feed rate is controlled by pressure applied to the spindle lever. Walking the drill bit is less likely, but a center punch is still recommended.<br /> <br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Drill_bits&diff=1746 2020-06-04T20:55:20Z

<p>PorterParker: Created page with &quot;A short overview of drill bits and their types&quot;</p> <hr /> <div>A short overview of drill bits and their types</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1745 2020-06-04T20:34:54Z

<p>PorterParker: /* Presses */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> A vice uses two jaws to compress a part and come in a variety of sizes. These are traditionally used to hold a workpiece while machining. Vices are often used as a makeshift press by attaching a cheater bar.<br /> ===Die Press===<br /> A shaped die is used to punch a shaped hole into a sheet of material. For example, a die press can be used to quickly punch multiple holes into sheet metal for [[rivets]].<br /> ===Arbor Press===<br /> A simple mechanical press for press fits or broaching.<br /> ===Hydraulic Press===<br /> Hydraulic presses can exert much more force than an arbor press using hydraulics. A cheap hydraulic press can easilly press bearings.<br /> <br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1706 2020-06-02T20:12:39Z

<p>PorterParker: /* Safety */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> {{Main|Health_and_Safety}}<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Threaded_Fasteners&diff=1705 2020-06-02T20:07:08Z

<p>PorterParker: /* Screw Types */</p> <hr /> <div>Threaded fasteners used in FS are most typically made of steel but are sometimes also made of stainless, titanium, or aluminum.<br /> =Standards=<br /> There are two main threaded fastener standards: metric and inch. Within these two categories lay additional standards set by various organisations. These standards may are often intercompatible but can differ in head size, strength, alloy, coating, pitch, and local avaliability.<br /> ==Metric==<br /> Metric screws are listed in the following way:&lt;code&gt;&lt;nowiki&gt;M6x25 x 1mm Class 8.8&lt;/nowiki&gt;&lt;/code&gt;. The M6 referes to the major diameter being 6mm, 25: the shaft length is 25mm, and the pitch is 1 thread per 1mm. A class 8.8 bolt is a medium strength steel bolt with a tensile strength of about 800MPa and about 80% of that being the yield strength.<br /> ===ISO===<br /> ===DIN===<br /> ===JIS===<br /> ==Inch==<br /> Inch screws are listed in the following way:&lt;code&gt;&lt;nowiki&gt;1/4-20 x 1 Grade 5&lt;/nowiki&gt;&lt;/code&gt;. The 1/4 is the major diameter of 1/4in, a thread pitch of 20 threads per inch, and a length of 1in. A grade 5 bolt is a medium strength steel bolt with a tensile strength of about _ksi and a yield strength of _ksi.<br /> ===SAE===<br /> [grades, charts, etc...]<br /> ===AN===<br /> =Screw Types=<br /> <br /> {| class=&quot;wikitable&quot;<br /> |-<br /> |Photo<br /> |Names<br /> |Description<br /> |-<br /> |[[File:hexhead_mcmaster.png|50px]]<br /> |Hex head<br /> |&lt;br /&gt;<br /> |-<br /> |[[File:12point_mcmaster.png|50px]]<br /> |Twelve point<br /> |&lt;br /&gt;<br /> |-<br /> |[[File:sockethead_mcmaster.png|50px]]<br /> |Socket head<br /> <br /> Allen® head<br /> |&lt;br /&gt;<br /> |-<br /> |[[File:shoulder_mcmaster.png|50px]]<br /> |Shoulder screw<br /> |&lt;br /&gt;<br /> |-<br /> |[[File:setscrew_mcmaster.png|50px]]<br /> |Set screw<br /> |&lt;br /&gt;<br /> |-<br /> |&lt;br /&gt;<br /> |Quarter turn<br /> <br /> [https://www.southco.com/en-us/product/hierarchy.html?hid=7345 DZUS® fastener]&lt;ref&gt;https://en.wikipedia.org/wiki/Dzus_fastener&lt;/ref&gt;<br /> |A specialty fastener that allows quick installation and removal of [[Body Panel|body panels]].<br /> |}<br /> <br /> =Nut Types=<br /> ==Deez Nutz==<br /> ===Hex Nut===<br /> ===Weld Nut / Riv-Nut===<br /> ==Locknut==<br /> Locknuts resist loosening. Other methods can be used to resist loosening: [[Washer#Lock washer|lock washers]], [[Safety Wire|safety wire]], [[Locking Adhesive|locking adhesive]], or design. Most locknuts are only designed to be installed a few times otherwise their loosening resistance is diminished.<br /> <br /> <br /> {| class=&quot;wikitable&quot; style=&quot;width: 1661px;&quot; data-mce-style=&quot;width: 1661px;&quot;<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;|Photo<br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Common Name<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;|Description<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;|&lt;br /&gt;<br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Jam nut<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;|&lt;br /&gt;<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;|&lt;br /&gt;<br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Nylon nut<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;|&lt;br /&gt;<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;|&lt;br /&gt;<br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Nylok<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;|&lt;br /&gt;<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;|&lt;br /&gt;<br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Distorted nut<br /> <br /> Stover nut<br /> <br /> K-nut / Jet-nut<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;|Different components of the nut can be distorted to prevent loosening. For example: thread pitch and eccentricity. The temperature range is limited only by the parent metal or its plating and can be reused approximately 10 times before its locking capability is diminished&lt;ref&gt;Barrett, Richard. [https://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19900009424.pdf|&quot;Fastener Design Manual&quot;], Nasa Reference Publication 1228 (1990) pp7&lt;/ref&gt;. A K-nut or Jet-nut is ideal for high temperature applications.<br /> |-<br /> | style=&quot;width: 39px;&quot; data-mce-style=&quot;width: 39px;&quot;| <br /> | style=&quot;width: 106px;&quot; data-mce-style=&quot;width: 106px;&quot;|Castle nut<br /> | style=&quot;width: 1476px;&quot; data-mce-style=&quot;width: 1476px;&quot;| <br /> |}<br /> <br /> ==Threaded Insert==<br /> =Fastener Characteristics (how to choose)=<br /> <br /> * Initial Tensioning<br /> * Initial Tightening Force<br /> ** Brings bolt close to &quot;proof load&quot;<br /> * Deformation of threads (pic)<br /> * Maintenance schedule<br /> <br /> =Torque Tension Calcs=<br /> =Further Reading=<br /> <br /> * [https://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19900009424.pdf NASA Fastener Design Manual]<br /> * Carroll Smith's ''Screw to Win''<br /> <br /> =References=<br /> &lt;references /&gt;&lt;br /&gt;<br /> <br /> [[category:Fasteners]]</div>

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PorterParker http://fswiki.us/index.php?title=Welding&diff=1699 2020-06-02T19:53:59Z

<p>PorterParker: /* Stick */</p> <hr /> <div>==General Tips==<br /> <br /> * If it’s not held, it will deform<br /> * If it is held, but has gaps, it will deform (i.e, a tube joint should be precise)<br /> * If welds are asymmetric, it will deform<br /> * Fillet welds deform more than flat welds<br /> * Your jig is the “upper limit” of accuracy<br /> * The ONLY way to ensure it does not deform, is to gusset. An aid is well-ordered tacking (4 points)<br /> &lt;br /&gt;<br /> <br /> 4130 steel gets brittle when welded. To fix, Heat treat (either with an oxy-acetelyne torch, or a proper oven treatment). A potential way to avoid this is to weld with ER70S6 filler&lt;span&gt;(weaker, but produces more mallable welds) ([https://www.lincolnelectric.com/en-ca/support/welding-how-to/Pages/chrome-moly-detail.aspx?utm referrer=https://www.google.com/ source]). Unless sufficiently proven, it would not be advised to design a frame with a &lt;3 FOS, without heat treatment. The usage of a single cylinder also without soft mounting may be enough to crack a non heat treated (or even heat treated?) frame.&lt;/span&gt;<br /> <br /> <br /> &lt;span&gt;Aluminum is more difficult generally, since the oxidation layer has a higher melting point than the layers underneath. So, a tendency to blow holes is the result. Not all aluminum alloys are weldable, and the ones that are will be very brittle unless heat treated properly in an oven.&lt;/span&gt;<br /> <br /> <br /> &lt;br /&gt;<br /> ==TIG==<br /> NOOOOOOOO YOU CAN'T JUST USE ONE HAND TO WELD<br /> <br /> <br /> <br /> <br /> Highly versatile. Control of heat and feed independently (one in each hand) - allowing for fine tuning of the weld to the material at hand. Can work for aluminum and steel. A good welder will be able to weld ~.06in aluminum, and .028 steel (1.5 mm and ~0.5mm respectively in proper units).<br /> <br /> <br /> The drawback is that it requires more skill, and more active work - making the welding slower and higher effort. While a beginner can learn to tack within less than 1h, to become capable of performing hours of structural welds takes more effort.<br /> ==MIG==<br /> haha, welding gun go brrrrrrr<br /> <br /> <br /> <br /> <br /> Same science principle of TIG, but now the heat and the feed are combined into one torch, with a wire spool instead of &quot;filler rods&quot; also serving as the electrode to close the circuit. Advantage? easy to learn, and if you weld alot of the same tube thicknesses, its &quot;set and forget&quot;. Fast and easy, while also allowing one hand use which makes reaching into difficult spots in the frame much easier. Disadvantage? harder to do thin and small stuff - .035in steel is roughly the limit. Welds are less pretty and slightly heavier. How much heavier? I've weighed a baja frame tacked and fully welded, and on a 72lb frame, the welds were 2.5lb. I dont have any numbers for TIG, but i'd be surprised if the difference is more than 1lb. The time saved however is substantial - that frame took ~5h of shop time (not welding time) to finish weld - from tacked frame tubes+tabs, to ready to paint. The formula frames i've worked on took multiple full days, by multiple welders.<br /> <br /> <br /> <br /> <br /> ==Stick==<br /> Does anyone use this?<br /> <br /> Baja lol<br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1698 2020-06-02T19:51:38Z

<p>PorterParker: </p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Cutting?==<br /> ===Plasma Cutting===<br /> ===Laser Cutting===<br /> ===Water Jetting===<br /> ==Mills and Lathes==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]<br /> Mills and lathes vary from small bench top tools to large floor models. They are more precise and universal than something like a drill press, although these machines can take longer to setup.<br /> <br /> Machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should be considered.<br /> <br /> Dimensions can be confirmed by either using the hand wheel markings, [https://en.wikipedia.org/wiki/Scriber scribing] and measuring, or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> There are [[Machining#CNC_Machining|CNC versions]] of both mills and lathes.<br /> ===Mills===<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed.<br /> <br /> ===Lathes===<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Be careful and take a class if your university has one. &lt;span style=&quot;color:red&quot;&gt;'''Formula students have died using lathes!'''&lt;/span&gt;<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1697 2020-06-02T19:35:00Z

<p>PorterParker: /* Lathes */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed. Machining technique varies depending on tool type/material and workpiece material. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should also be considered.<br /> <br /> Dimensions can be confirmed by either scribing and measuring or using a Digital Read Out (DRO) if installed.<br /> <br /> ==Lathes==<br /> The [https://en.wikipedia.org/wiki/Metal_lathe metal lathe] rotates a spindle with a chuck to hold the workpiece. If the workpiece extends far past the chuck, a tailstock with a livecenter or other support can be used. Lathe tools are attached to a carriage and controlled in multiple axes with hand wheels.<br /> <br /> Tools are commonly used for facing, turning, boring, drilling, reaming, and threading. Just like milling: machining technique varies depending on tool type/material and workpiece material/size. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should also be considered.<br /> <br /> Dimensions can be confirmed by either scribing and measuring or using a [https://en.wikipedia.org/wiki/Digital_read_out Digital Read Out (DRO)] if installed.<br /> <br /> Lathes are also one of the most dangerous tools in a workshop. Large lathes won't even flinch while sucking in the user! Formula students have died using lathes.<br /> <br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1696 2020-06-02T19:11:50Z

<p>PorterParker: /* Mills */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|200px|right|middle|thumb|A vertical milling machine with a vice and DRO installed]]The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed. Machining technique varies depending on tool type/material and workpiece material. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should also be considered.<br /> <br /> Dimensions can be confirmed by either scribing and measuring or using a Digital Read Out (DRO) if installed.<br /> <br /> ==Lathes==<br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1695 2020-06-02T19:09:49Z

<p>PorterParker: /* Mills */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> [[File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg|right|top|thumb|A vertical milling machine with a vice and DRO installed]]The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed. Machining technique varies depending on tool type/material and workpiece material. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should also be considered.<br /> <br /> Dimensions can be confirmed by either scribing and measuring or using a Digital Read Out (DRO) if installed.<br /> <br /> ==Lathes==<br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg&diff=1694 2020-06-02T19:07:56Z

<p>PorterParker: A full view of a Sharp Machinery 3 axis vertical mill. An example of a Bridgeport variant. https://commons.wikimedia.org/wiki/File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg</p> <hr /> <div>== Summary ==<br /> A full view of a Sharp Machinery 3 axis vertical mill. An example of a Bridgeport variant.<br /> <br /> https://commons.wikimedia.org/wiki/File:Sharp_3_Axis_Vertical_Mill_Full_View.jpg</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1693 2020-06-02T19:03:05Z

<p>PorterParker: /* Mills */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> The most typical milling machine is the [https://en.wikipedia.org/wiki/Milling_(machining)#Vertical_mill vertical milling machine]. In this configuration, the workpiece held to the table typically within a vice and elevated with parallels. The table is controlled in the XYZ axes. The tool is held with a [https://en.wikipedia.org/wiki/Collet collet] or [https://en.wikipedia.org/wiki/Chuck_(engineering)#Drill_chuck drill chuck] and spun by the spindle. The spindle speed and plunge axis is also controlled by the user.<br /> <br /> Tools such as end mills, drill bits, reamers, fly cutters, and saws can be installed. Machining technique varies depending on tool type/material and workpiece material. Topics such as [https://en.wikipedia.org/wiki/Speeds_and_feeds speeds and feeds], heat generated, and [https://en.wikipedia.org/wiki/Cutting_fluid lubrication] should also be considered.<br /> <br /> Dimensions can be confirmed by either scribing and measuring or using a Digital Read Out (DRO) if installed.<br /> <br /> ==Lathes==<br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1690 2020-06-02T18:34:50Z

<p>PorterParker: /* CNC Machining */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> ==Lathes==<br /> ==CNC Machining==<br /> Not all teams may have access to a CNC. You do not need CNC to make a formula car but it is recommended for complex, high tolerance, or high quantity parts. Talk to local machine shops and trade schools, they may be willing to sponsor your team with CNC services.<br /> <br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations<br /> <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1689 2020-06-02T18:28:09Z

<p>PorterParker: /* Safety */</p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> If your team is going to be using any of the tools below, please wear the correct [https://en.wikipedia.org/wiki/Personal_protective_equipment Personal Protective Equipment (PPE)] for the work being done.<br /> <br /> Typical shop dress code is: cotton short sleeve shirt, jeans, close-toed shoes, no jewelry, and hair tied out of the way.<br /> <br /> Recommended PPE includes safety glasses and hearing protection. Occasionally additional PPE is required such as a full face shield, respirator, or gloves. <br /> <br /> ''NOTE: Using rotating machines with gloves or a long sleeve shirt might seem safer, but it is actually more dangerous due to the risk of getting sucked in.''<br /> <br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> ==Lathes==<br /> ==CNC Machining==<br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Machining&diff=1687 2020-06-02T18:11:33Z

<p>PorterParker: </p> <hr /> <div>A list of subtractive manufacturing tools commonly used in Formula for any material. Theory, safety, pros/cons, photos, cost, etc...<br /> When this gets too large we can consider separating it into other pages.<br /> ==Safety==<br /> PPE!<br /> ==Presses==<br /> ===Vice===<br /> ===Die Press===<br /> ===Arbor Press===<br /> ===Hydraulic Press===<br /> ==Saw==<br /> ===Hand Saw===<br /> ===Band Saw===<br /> ==Grinder==<br /> ===Rotary Tool===<br /> Also known by the trade name [https://en.wikipedia.org/wiki/Dremel Dremel®], the rotary tool is ideal for small and delicate work. Depending on the bit installed, the tool can grind, sand, cut, or polish.<br /> ===Die Grinder===<br /> Die grinders are typically more powerful than a rotary tool. The extra power can turn larger bits. A 1&quot; coarse grinding bit can be used to [[Tube_Frame#Cutting_tubes|cope tubes]].<br /> ===Angle Grinder===<br /> Angle grinders are even more powerful than a die grinder but also larger, less precise, and more dangerous. Different disks can be installed on the tool for different types of work. A grinder wheel can quickly remove material. Flap disks are convenient for finishing or cleaning. Cutoff disks are for cutting ONLY! do not attempt to grind with a cutoff disk because they are known to shatter into a million pieces and hit you!<br /> <br /> When using an angle grinder, be aware of where your sparks are going. Do not remove the shield! Disks can and will shatter. <br /> ===Bench Grinder===<br /> ==Drill==<br /> ===Hand Drill===<br /> ===Drill Press===<br /> ==Taps and Dies==<br /> ==Laser Cutting==<br /> ==Water Jetting==<br /> ==Mills==<br /> ==Lathes==<br /> ==CNC Machining==<br /> Computer Numerically Controlled (CNC) machining is a process which takes programmed tool paths via user input in order to machine a part. Programming the tool paths is done in a Computer Aided Manufacturing (CAM) software, which allows the programmer to choose the tools used for machining and visually simulate the machining if the part. The program is then transferred to the machine to do the work.<br /> * Complex shapes can be made with CNC compared to manual machining<br /> * Parts, tools, and software can be more expensive than manual machining<br /> * Involves additional programming time and testing<br /> * Precision and finish is generally higher with CNC parts as everything is controlled by a computer and the ability to climb mill.<br /> ===2 Axis===<br /> 2 Axis machining generally the X and Y axis <br /> ===2.5 axis machining===<br /> ===3 Axis===<br /> ===Multi-axis===<br /> Multi-axis CNC Machining is any CNC machining performed on a machine with greater than 3 axis (degrees of freedom) control. Different variations <br /> ==Further Reading==<br /> * [https://www.youtube.com/playlist?list=PLF06SHGgSg4Fk5-yeh8DN3g6ZgaM0tbk7 MIT Machine Shop Videos (Youtube Playlist)]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> [[Category:Manufacturing Techniques]]</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1624 2020-05-24T20:36:01Z

<p>PorterParker: /* Welding */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules. One thing to remember is that the frame is basically a glorified bracket. As such, the frame designer is primarely concerned with accomedating other systems - in approximate order of importance:<br /> * Ergonomics: the driver<br /> * Suspension: A-arm pickup points, and less importantly the damper linkage (it can meet the design requirements in a few arrangements usually)<br /> * Powertrain/drivetrain: differential mounting is usually heavily reliant on frame. Engine removability!<br /> * Aero: things like ground clearence and framerail width for undertray.<br /> * Electrical: can usually work around everyone, right?<br /> <br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> <br /> <br /> Note that because some tubes will inevitably take bending (primarely the side impact structure, due to impossible triangulation from the big empty space the driver occupies), there should be emphasis on reducing tube aspect ratio (by either upping diameter or reducing length), and adding gussets.<br /> ===Tube Choice===<br /> ====Alloys====<br /> [[Steel#1000 Series|10XX steel]] is cheap, easy to weld, readily available, and easy to machine.<br /> <br /> <br /> [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat required).<br /> <br /> <br /> Aluminum?<br /> <br /> ====Method====<br /> ERW, DOM<br /> <br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|center|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;Image16.png&quot; src=&quot;/images/thumb/9/9d/Image16.png/300px-Image16.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;201&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/9/9d/Image16.png 1.5x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit.You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> [[File:Image99.png|center|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> <br /> (Fixture gallery?)<br /> <br /> ===Welding===<br /> {{Main|Welding}}<br /> Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;&quot; src=&quot;/images/thumb/0/0b/Image152.png/300px-Image152.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;176&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/thumb/0/0b/Image152.png/450px-Image152.png 1.5x, /images/thumb/0/0b/Image152.png/600px-Image152.png 2x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;Torsional stiffness FEA in solidworks<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1622 2020-05-24T20:34:55Z

<p>PorterParker: /* Fixtures */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules. One thing to remember is that the frame is basically a glorified bracket. As such, the frame designer is primarely concerned with accomedating other systems - in approximate order of importance:<br /> * Ergonomics: the driver<br /> * Suspension: A-arm pickup points, and less importantly the damper linkage (it can meet the design requirements in a few arrangements usually)<br /> * Powertrain/drivetrain: differential mounting is usually heavily reliant on frame. Engine removability!<br /> * Aero: things like ground clearence and framerail width for undertray.<br /> * Electrical: can usually work around everyone, right?<br /> <br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> <br /> <br /> Note that because some tubes will inevitably take bending (primarely the side impact structure, due to impossible triangulation from the big empty space the driver occupies), there should be emphasis on reducing tube aspect ratio (by either upping diameter or reducing length), and adding gussets.<br /> ===Tube Choice===<br /> ====Alloys====<br /> [[Steel#1000 Series|10XX steel]] is cheap, easy to weld, readily available, and easy to machine.<br /> <br /> <br /> [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat required).<br /> <br /> <br /> Aluminum?<br /> <br /> ====Method====<br /> ERW, DOM<br /> <br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|center|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;Image16.png&quot; src=&quot;/images/thumb/9/9d/Image16.png/300px-Image16.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;201&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/9/9d/Image16.png 1.5x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit.You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> [[File:Image99.png|center|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> <br /> (Fixture gallery?)<br /> <br /> ===Welding===<br /> {{Main|Welding}}<br /> <br /> <br /> <br /> <br /> : ''Main page: &lt;a title=&quot;Welding&quot;&gt;Welding&lt;/a&gt;''Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> <br /> <br /> <br /> (notes on welding chromoly vs DOM. recommended filler/wire/electrodes) (NOTE - Added to the welding section)<br /> <br /> <br /> <br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;&quot; src=&quot;/images/thumb/0/0b/Image152.png/300px-Image152.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;176&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/thumb/0/0b/Image152.png/450px-Image152.png 1.5x, /images/thumb/0/0b/Image152.png/600px-Image152.png 2x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;Torsional stiffness FEA in solidworks<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1621 2020-05-24T20:34:29Z

<p>PorterParker: /* Alloys */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules. One thing to remember is that the frame is basically a glorified bracket. As such, the frame designer is primarely concerned with accomedating other systems - in approximate order of importance:<br /> * Ergonomics: the driver<br /> * Suspension: A-arm pickup points, and less importantly the damper linkage (it can meet the design requirements in a few arrangements usually)<br /> * Powertrain/drivetrain: differential mounting is usually heavily reliant on frame. Engine removability!<br /> * Aero: things like ground clearence and framerail width for undertray.<br /> * Electrical: can usually work around everyone, right?<br /> <br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> <br /> <br /> Note that because some tubes will inevitably take bending (primarely the side impact structure, due to impossible triangulation from the big empty space the driver occupies), there should be emphasis on reducing tube aspect ratio (by either upping diameter or reducing length), and adding gussets.<br /> ===Tube Choice===<br /> ====Alloys====<br /> [[Steel#1000 Series|10XX steel]] is cheap, easy to weld, readily available, and easy to machine.<br /> <br /> <br /> [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat required).<br /> <br /> <br /> Aluminum?<br /> <br /> ====Method====<br /> ERW, DOM<br /> <br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|center|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;Image16.png&quot; src=&quot;/images/thumb/9/9d/Image16.png/300px-Image16.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;201&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/9/9d/Image16.png 1.5x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit.You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> [[File:Image99.png|center|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum]<br /> <br /> <br /> (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> <br /> (Fixture gallery?)<br /> <br /> <br /> <br /> <br /> ===Welding===<br /> {{Main|Welding}}<br /> <br /> <br /> <br /> <br /> : ''Main page: &lt;a title=&quot;Welding&quot;&gt;Welding&lt;/a&gt;''Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> <br /> <br /> <br /> (notes on welding chromoly vs DOM. recommended filler/wire/electrodes) (NOTE - Added to the welding section)<br /> <br /> <br /> <br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> &lt;a class=&quot;image&quot;&gt;&lt;img alt=&quot;&quot; src=&quot;/images/thumb/0/0b/Image152.png/300px-Image152.png&quot; decoding=&quot;async&quot; width=&quot;300&quot; height=&quot;176&quot; class=&quot;thumbimage&quot; srcset=&quot;/images/thumb/0/0b/Image152.png/450px-Image152.png 1.5x, /images/thumb/0/0b/Image152.png/600px-Image152.png 2x&quot;&gt;&lt;/a&gt; &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;Torsional stiffness FEA in solidworks<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Nose_cone&diff=1620 2020-05-24T20:32:59Z

<p>PorterParker: Created page with &quot;The nose cone is abody panel at the forwardmost point of the vehicle. ==Design== The nose cone can be made from similar materials that body panels are made from...&quot;</p> <hr /> <div>The nose cone is a[[Body Panel|body panel]] at the forwardmost point of the vehicle.<br /> ==Design==<br /> The nose cone can be made from similar materials that body panels are made from. It is important to to shape the nose cone to be the least phallic as possible, otherwise your team will be laughed at.<br /> <br /> <br /> <br /> <br /> Rules stuff<br /> <br /> <br /> <br /> <br /> [[Category:Body and Aero]]</div>

PorterParker http://fswiki.us/index.php?title=Spaceframe&diff=1614 2020-05-24T20:14:57Z

<p>PorterParker: Redirected page to Tube Frame</p> <hr /> <div>#REDIRECT[[Tube Frame]]</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1613 2020-05-24T20:12:07Z

<p>PorterParker: /* Fixtures */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ===Tube Choice===<br /> ====Alloys====<br /> [[Steel#1000 Series|10XX steel]] is cheap, easy to weld, readily available, and easy to machine.<br /> <br /> <br /> [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat required).<br /> <br /> <br /> Aluminum?<br /> ====Method====<br /> ERW, DOM<br /> <br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> <br /> (Fixture gallery?)<br /> <br /> ===Welding===<br /> {{Main|Welding}}Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> <br /> <br /> <br /> (notes on welding chromoly vs DOM. recommended filler/wire/electrodes)<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1612 2020-05-24T20:10:47Z

<p>PorterParker: /* Design */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ===Tube Choice===<br /> ====Alloys====<br /> [[Steel#1000 Series|10XX steel]] is cheap, easy to weld, readily available, and easy to machine.<br /> <br /> <br /> [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat required).<br /> <br /> <br /> Aluminum?<br /> ====Method====<br /> ERW, DOM<br /> <br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===Welding===<br /> {{Main|Welding}}Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> <br /> <br /> <br /> (notes on welding chromoly vs DOM. recommended filler/wire/electrodes)<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1611 2020-05-24T19:57:25Z

<p>PorterParker: /* Welding */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===Welding===<br /> {{Main|Welding}}Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference (rules link).<br /> <br /> <br /> <br /> <br /> (notes on welding chromoly vs DOM. recommended filler/wire/electrodes)<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1610 2020-05-24T19:54:08Z

<p>PorterParker: /* Fixtures */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===Welding===<br /> {{Main|Welding}}<br /> Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult.<br /> <br /> &lt;notes on welding chromoly vs DOM. recommended filler/wire/electrodes&gt;<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1608 2020-05-24T19:49:33Z

<p>PorterParker: /* Welding */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===Welding===<br /> {{Main|Welding}}<br /> Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult.<br /> <br /> &lt;notes on welding chromoly vs DOM. recommended filler/wire/electrodes&gt;<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1606 2020-05-24T19:48:00Z

<p>PorterParker: /* Welding */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===[[Welding|Welding]]===<br /> Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult.<br /> <br /> <br /> <br /> <br /> &lt;notes on welding chromoly vs DOM. recommended filler/wire/electrodes&gt;<br /> <br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1605 2020-05-24T19:41:52Z

<p>PorterParker: /* Fixtures */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum datum] (for example the front bulkhead). From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).<br /> <br /> ===[[Welding|Welding]]===<br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Tube_Frame&diff=1599 2020-05-24T19:32:14Z

<p>PorterParker: /* Cutting tubes */</p> <hr /> <div>[[Category:Chassis]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximised by triangulating the tubing to ensure that the tubes are not loaded in bending.<br /> <br /> <br /> <br /> <br /> ==Design==<br /> Designing the tube frame is a compromise between structural rigidity, weight and manufacturing complexity.<br /> ===Triangulation===<br /> Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?<br /> ==Manufacturing==<br /> Many teams use &quot;VR3 Engineering&quot; to produce their tubeset. This is an all inclusive (bending and cutting) service, and will be in the 3000-5000$ range for frame and suspension, depending on complexity and shipping. The upside is substantial time saved - their process is nearly fully automated, and the manufacturing process limits are fairly minimal.<br /> ===Cutting tubes===<br /> Cutting tubes to intersect each other is called coping or notching. Tubes can be notched by hand typically using a hole saw notcher, bench grinder, or die grinder. This process is very time consuming and meticulous. Tubes can also be profiled using a water jet or laser cutter.<br /> <br /> ===Tube bending===<br /> Bending the tubes by hand<br /> <br /> <br /> <br /> <br /> Using CNC tube benders<br /> <br /> <br /> <br /> Any motorcycle builders around? They can have tools for 1&quot; tubing.<br /> <br /> <br /> <br /> <br /> ===VR3 Engineering - Specifics===<br /> This is a schematic of the tube cutting setup:<br /> [[File:image16.png|right|middle|thumb]]<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> &lt;a class=&quot;internal&quot; title=&quot;Enlarge&quot;&gt;&lt;/a&gt;<br /> <br /> <br /> <br /> <br /> Their machine has a vertical mill head (1/8in diameter) and a rotating feeder cuff. This means that in the default 3-axis configuration (and for round tubes), the end-mill is always perpendicular to the tube surface being cut. This matters for tolerances/fit:<br /> <br /> <br /> <br /> <br /> You can request them to use the 4th axis on round tubes where a very tight tolerance is required. For the Ryerson 2020 car, we asked for it on the a-arm tubes, which are .5in diameter.But for all other frame tubes, it is of no consequence, the tube will still fit very well, as intended.<br /> <br /> <br /> <br /> <br /> [[File:Image99.png|right|middle|thumb|3 vs 4 axis ]]<br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> <br /> ===Fixtures===<br /> Fixturing is central to the accuracy of the finished tube frame. Fixtures can be made in MDF, plywood or sheet metal.<br /> ===[[Welding|Welding]]===<br /> ==Analysis==<br /> Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]<br /> <br /> <br /> * To test totsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity<br /> * To stiffen frame where needed, and change up layouts<br /> * To make sure it doesnt break, or is too close to low FOS where welds may crack<br /> * Frequency analysis perhaps?&lt;br /&gt;<br /> <br /> Problem:<br /> * Solid body FEA with a triangle mesh is too time consuming, for a 50+ tube frame. IF you have to, export small sections and do a small contained study (outlined below)<br /> * Theres a quicker method - beam FEA. It makes a mesh of “pie cuts” of tubes. Way less mesh data, but very good accuracy still - a whole frame sim can run in ~30sec, on a laptop.<br /> * It does not capture tab interfaces etc, but it does caputre member stresses.<br /> * Cannot do an assembly simulation in it, but can simulate pivotable “joints”<br /> <br /> ===Torsional FEA (Beam sim) Workflow (Solidworks):===<br /> <br /> # Put in a mock “engine” as just a bunch of tubes, triangulated to be stiff.<br /> # Put in mock a-arms (lower arms only, upper arent needed unless doing camber stiffness) and pushrods<br /> # Modify the appropriate joints to “hinges” (by right clicking on a member in the cutlist folder in the tree, and clicking &quot;edit definition&quot;)<br /> # Apply “immovable (allowing rotation) fixtures to 3 wheel, apply 100lb upwards to the 4th.<br /> # Bellcrank can be done but its complex computationally and my best way was to treat as direct actuation (getting decently accurate), and then performing a separate exported section get simulated with an assembly simulation - with the actual bellcrank, tabs etc. Then just add up the two deflections.<br /> # [[File:image75.png|right|middle|thumb|FEA setup ]]Run, then view results! to understand if it makes sense, animate it - with the stress view.<br /> <br /> Beam FEA Notes:<br /> * Beam FEA doesnt like short members. If you have a short member, ask yourself if it can be “combined” (i.e combine operation) with another. An example is suspension tabs. In our case, they will be combined with the arm tubes.<br /> * Beam FEA also doesnt like arcs - sharper bent tubes (making arcs that are fairly long, like 3inch plus) as nodes should be avoided, as ive had a bunch of weird bugs in FEA where the SIM node of the RRH being an arc just randomly detached<br /> * Beam FEA works with “nodes” that it automatically computes. You can get it to manually compute, based on custom set distances - this helps eliminate (filter out) 2 super close together nodes. But keep in mind, every time you recompute the nodes, your fixtures may change - since their referenced node will change number.<br /> [[File:image41.png|right|middle|thumb|Configuring Hinge Joints]]<br /> <br /> ===Solid-Body Frame FEA (Soldworks)===<br /> Its not computationally realistic to do a solid body simulation for the entire frame. As such, I recommend exporting a section of interest, and ananlyzing it seperately. For example, the bellcrank mounting, or a-arm tabs. In the case of the bellcrank, you'd be best to include the actual bellcrank as well and perform an assembly simulation. You never know how much it will contribute!<br /> <br /> How to export a section? Start from having a fully merged body that includes the tubes/tabs of interest. The extruded tabs have to properly intersect the tube for merging to work. You can use the &quot;combine&quot; feature (just search for it in the command search box) to combine all the bodies together. Once done, right click the body, and click &quot;insert into new part&quot;.<br /> <br /> Proceed with solid body FEA - NOT beam FEA. Meshing is sometimes tricky, so the addition of fillets as well as mesh control (mesh per part size) helps auto refine the mesh in the sharp edges and prevent the meshing from failing.<br /> ==Frame/Susp - Sending out==<br /> If using VR3 engineering to produce your tubeset for you, you have to send out a:&lt;br /&gt;<br /> * BOM Drawing<br /> * VR3 template excel sheet, with a qtys summary<br /> * Once quote approved, indiv tube files.<br /> &lt;br /&gt;Fortunately, a superb guide already exists - on the VR3 website. Its not a super light/easy thing to figure out, and yes you will have some late nights (or one all nighter) trying to send the frame out - usually, due to struggling with the BOM etc - but what do you expect? Not everything in life is a light read.&lt;br /&gt;The doc is “SAE Student Guideline”, and is in their documents section of [https://vr3.ca/technical-documents/ their website]<br /> &lt;br /&gt;&lt;br /&gt;</div>

PorterParker http://fswiki.us/index.php?title=Chain_Drive&diff=1558 2020-05-23T23:57:59Z

<p>PorterParker: </p> <hr /> <div>A chain and sprocket [[Drivetrain|drive system]] requires lubrication and a [[tensioner|tensioner]].<br /> ==Chains==<br /> explain motorcycle chain sizes, ratings.<br /> <br /> Chains can be easily lengthened or shortened using quick release links.<br /> ===Sealed chain===<br /> Sealed chains use o-rings to seal in a lubricant, great for daily driving. Also used in racing applications. Very common in motorcycle shops.<br /> ===Non-Sealed chain===<br /> Non-sealed requires more frequent lubrication application and are commonly used for motocross or low mileage applications.<br /> ==Sprockets==<br /> Sprockets are made of [[Steel|steel]], [[Aluminum|aluminum]], or [[Titanium|titanium]] and can replaced to change the [[Drivetrain#Final_Drive_Ratio|final drive ratio]]. Sprockets can be bought or easily made by [[Machining#Laser Cutting|laser-cutting]], [[Machining#Water Jetting|water-jetting]], or [[Machining#CNC Machining|CNC machining]].<br /> <br /> As the number of teeth decrease, the sprocket will approach a polygon instead of a circle. This is called the polygon effect or chordal action and results in a variation in speed output (Imagine driving on square wheels).&lt;ref&gt;[http://chain-guide.com/basics/2-2-1-chordal-action.html http://chain-guide.com/basics/2-2-1-chordal-action.html]&lt;/ref&gt;<br /> ==Drivetrain Shield==<br /> Chain drives have specific shielding rules in FSAE covered in T.5.2.7 (link to rules) (what about FS?).<br /> ==Failure Modes==<br /> If there is excessive sprocket wear, improper chain [[Tensioner|tension]], improperly installed quick release, no lubricant, or if the chain drive is not in the same plane there WILL be a failure. Chain failures can be extremely dangerous for both the vehicle and nearby people. (more on failure modes/design flaws?)&lt;br /&gt;&lt;br /&gt;+No slip possible in chain drive without failure [https://www.myodesie.com/wiki/index/returnEntry/id/3058#Chain%20Drive%20Advantages https://www.myodesie.com/wiki/index/returnEntry/id/3058#Chain%20Drive%20Advantages]<br /> ==References==<br /> &lt;references /&gt;<br /> <br /> [[Category:Internal Combustion]][[Category:Electric Vehicle]]</div>

PorterParker