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Racecar Design Using Solid Edge. Presented to: The Solid Edge Global Summit Orlando, FL February 19, 2003 Presented by: Jeffrey Berger fin - el. Outline. Fin-el History Fin-el Services Using Solid Edge in Motorsports Design FABCAR Project Gallery of Other Designs. Fin-el History.
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Racecar Design Using Solid Edge Presented to: The Solid Edge Global Summit Orlando, FL February 19, 2003 Presented by: Jeffrey Berger fin-el
Outline • Fin-el History • Fin-el Services • Using Solid Edge in Motorsports Design • FABCAR Project • Gallery of Other Designs
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.
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
Fin-el Services • Industrial Design • Motorsports • Consumer products • Toys • Mechanical Design • Components • Equipment • Mechanisms • Design optimization
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.
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
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
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’
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
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
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
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
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
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
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
Racecar Design Using Solid Edge Presented to: The Solid Edge Global Summit Orlando, FL February 19, 2003 Presented by: Jeffrey Berger fin-el
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Summary • Solid Edge – an excellent tool for motorsports design