Racecar Design Using Solid Edge

1. Racecar Design Using Solid Edge Presented to: The Solid Edge Global Summit Orlando, FL February 19, 2003 Presented by: Jeffrey Berger fin-el

2. Outline • Fin-el History • Fin-el Services • Using Solid Edge in Motorsports Design • FABCAR Project • Gallery of Other Designs

3. Fin-el History • Fin-el is a design and engineering firm in Indianapolis that specializes in providing services for the motorsports industry. • Began as the Engineering Department of US Centrifuge in Indianapolis. • In 1999, Fin-elbegan operating as an independent company offering a wide array of services and software.

4. Fin-el History • Fin-el is a design and engineering firm in Indianapolis that specializes in providing services for the motorsports industry. • Began as the Engineering Department of US Centrifuge in Indianapolis. • In 1999, Fin-elbegan operating as an independent company offering a wide array of services and software. 1998 2nd Place Winner

5. Fin-el Services • Industrial Design • Motorsports • Consumer products • Toys • Mechanical Design • Components • Equipment • Mechanisms • Design optimization

6. Fin-el Services • Analyses • Finite element stress and vibration analysis • Motion studies • Virtual reality simulations • Computational fluid dynamic analysis • Visit our comprehensive web site at www.fin-el.com for more details about our services.

7. Using Solid Edge in Motorsports Design • Fin-el uses Solid Edge as its core design software to complete all of its design projects because of its: • ease of use • capabilities • ability to interface with a wide variety of other programs • We will look at the FABCAR FDSC/03 design project to illustrate these features

8. FABCAR Project • We will look at following aspects of the FABCAR FDSC/03 design project and how Solid Edge was involved. • Overall Design Approach • Overall Workflow • Project Management • Body Styling • Component Design • Analyses • Manufacturing • Documentation

9. FABCAR Project • Overall Design Approach • Establish a ‘gatekeeper’ to manage the overall design • Start the overall design using a top-down approach • Incorporate bottom-up designed components • Use rendering throughout the design process to enhance communication • Work with manufactures during design process to ensure parts can be made within design parameters • Don’t be too eager to ‘cut chips’

10. FABCAR Project • Overall Workflow • Develop overall 2D layout from hand sketches and required dimensions • Create a single part file for the entire body • Add known parts such as wheels and tire, driver, engine, and gearbox • Add suspension geometry • Developing major components • Add minor components • Add ‘connection’ components • Break bodywork down into subcomponents • Check interferences

11. FABCAR Project • Project Management • Ensure all designers are properly linked to network. • Establish a master ‘gatekeeper’ of overall design • Establish a Master Part List file prior to starting design • Establish folders in part storage vault on server as desired • Establish a guideline to direct which fields should be completed in the properties section for each part and assembly • Using Insight ensures overall design remains synchronized between all designers • Using Insight greatly simplifies the gatekeepers job

12. FABCAR Project • Body Styling • Execute initial body design in one part • Create ‘sub-parts’ and use Boolean additions or subtractions within overall body part file to simplify modeling of complex geometries • Use Part Painter feature to give body par a more realistic appearance • Create your own custom colors for items such as lights and windows • Create separate parts for emblems and decals and apply textures for realistic appearance • Don’t forget to turn on Reflections and Textures in rendering set-up

13. FABCAR Project • Component Design • Begin by building a few part ‘compound’ parts to quickly establish a design flow • Construct or import files for vendor parts or previously design parts to be used • Once the overall design concept is established, start breaking compound parts down into individual parts • Design ‘connector’ parts such as brackets, mounts, wiring and plumbing in place. Xpress Route is an excellent tool for this Insert a chassis bitmap image

14. FABCAR Project • Analyses • Determine the optimum file format to import to each analysis program • Determine which parts and assemblies are targeted for each type of analysis • Stress and stiffness • Frequency response • Kinematic study • CFD • Heat Transfer • Save copies of each file to allow simplification to be made to optimize the overall analysis process • Save copies of these manipulated files in the formats required for each analysis program – bind information to Part files through Insight

15. FABCAR Project • Manufacturing • Use renderings of complex part and assembly concepts to discuss manufacturing options before finalizing the designs • Discuss formats/file types required by manufactures early in design process to simplify the transition – bind information to Part files through Insight • In addition to their native format, save parts in file types required by the manufactures • Create associative drawing files of parts and assemblies using SE Draft as required Insert Upright Rendering

16. FABCAR Project • Documentation • Use Exploded and Cutaway tools in SE Assembly to create images and diagrams for manuals and assembly/disassembly guidelines • Place views of sub-assemblies in SE Draft and use the Parts List and Ballooning tool to easily create associative BOM’s • Use the Rendering tools in SE Assembly to create photo-realistic image files for use in manuals, sponsorship packages, programs, presentations, proposals, and reports Show an exploded view dft file w/ BOM

17. FABCAR Project

18. Racecar Design Using Solid Edge Presented to: The Solid Edge Global Summit Orlando, FL February 19, 2003 Presented by: Jeffrey Berger fin-el

19. Gallery of Other Designs Ferrari F1 2020 Concept

20. Gallery of Other Designs Ferrari F1 2020 Team Concept

21. Gallery of Other Designs BMW F1 2020 Concept

22. Gallery of Other Designs SJB Spa GT Car Concept

23. Gallery of Other Designs Ferrari 555GT Concept

24. Gallery of Other Designs BMW 406GT Concept

25. Gallery of Other Designs Porsche GT Concept

26. Gallery of Other Designs Porsche GT Racer Concept

27. Gallery of Other Designs BMW Rally Car Concept

28. Gallery of Other Designs SJB F1/2 Supercar Concept

29. Gallery of Other Designs BMW Isetta 2002 Concept

30. Gallery of Other Designs Mustang Cobra Suspension Components

31. Gallery of Other Designs Toy Car Playset

32. Summary • Solid Edge – an excellent tool for motorsports design