Regional Competition

Who Are We?

• We are LunAR, an ‘F1 in Schools’ competition team from The Crypt School, Gloucester. • This is our third year entering the

competition, with our previous teams being very successful– winning the best rookie team and competing at the national competition.

Meet The Team• LunAR comprises of six key members, all

with different roles which are adapted to their talents. We also have a support team of a further three members to ensure that we reach the highest level of success in the competition. These are the cool ones. The crème de le crème.• We are hoping to exceeded our predecessors

the regional competition in Exeter (on the 3rd of February) which will allow us to race at national level, and hopefully then at an international level.

Donny Wong

Project Manager:• Delegation of work

to team members• Ensuring effective

communication with other team members• Production of car

designs

William Price

Graphics and Design Engineer:• Production of

graphics• Website design

and production • Production of car

designs

Jack Munday

Manufacturing Engineer: • Production of

designs for the car• Find and

communicate with manufacturing companies• Final finishing on

the car

Harry McLaren

Finance and Sponsorship Manager:• Monitor the

allocation of sponsorship funds to specific areas of the project• Aid in logistical

organisation of awareness-raising events

Alex McIlwraith

Marketing and Sponsorship Manager:• Production of

portfolio and such materials• Public relations,

particularly with sponsors

Ben Attwood

Quality Assurance and Resource Manager:• Check all car

designs against regulations• Source all

equipment, liaising with the finance manager

Ryan Taylor

Design Consultant and External Quality Assurance:• Aid the design

team giving recommendations• Help attain a finish

on the car

Jordan Williams

Testing Engineer:• Production of

facilities and equipment required to test car• Conduct tests to

improve the car and give feedback to other team members

Max Thomas

Testing Engineer:• Production of

facilities and equipment required to test car• Conduct tests to

improve the car and give feedback to other team members

Our Logo

Planning the Project

• Regular team meetings• Donny specifically allocated roles in order

to make sure that each of the members had an idea of what to do.• Gantt Chart

Our GoalsShort-term goals:

• Establish a strong, professional image by production of business cards and presentations at school.• Plan effectively for a high

quality car design.• Produce a professional

sponsorship prospectus to attract possible sponsors.

Long-term goals:

• Sustain strong relationships with at least 3 sponsors

• To maintain a well-managed team image that will be built up in the early stages of the project.

• To design and manufacture a car ourselves which will race at under 1.15 seconds at the regional competitions.

Projecting Risks

• Along with planning, we created a list of possible risks and area which could go wrong in our campaign, how they could impact on our success and also how they could be prevented. We used this as a means of checking our progress and it helped us to minimise possible risks as we had already taken steps to prevent them.

Resource Management

• Organising events for the teams as well as ensuring that everyone has a job to do• Quiz planning (on LunAR / F1 theme)

Ensuring sufficient materials available for projects

The Gantt Chart

Scope

• Understanding what we had to do in a given time using the Gantt chart• Assessing the size of each task• Communication and planning were key• Understanding restrictions in design and

planning

Communication

• CommunicationUnderstanding

Efficiency in work• Social media • Communicate with those interested in project• Communicate with each other

What makes a fast car?

• Low friction• Low skin drag• Low mass• Effective design

High velocity

Design Process – Software used

• Autodesk Inventor Professional 2015• Advantages and drawbacks

• Cinema 4D• SolidWorks software package• Home use and school use

Development of the car – stages of design

• Choker / initial ideas• Apollo• Regulatory problems

• Lift-Off• Non-linear development

CNC Router

Wheel Materials

• Oilon, Delrin and Turcite would be the best materials to use

SPECIFICATION: ABS Acetron Aluminium Delrin Lexan Mahoghany Nylatron Oak Oilon PET PLA TurciteChemically Lubricating? N N N N N N N N Y N N YColours M M M M N/A N/A M M

Density (g/cm3 ) (ISO 1183-1) 1.05 1.38 2.70 1.49 11.90 0.60 1.14 0.71 1.13 1.38 1.24 1.49Frictional Coeffeicent (Dynamic) 0.5 0.25 1.05 - 1.35 0.054 0.21 / 0.2 0.54-0.62 0.15 / 0.6 0.022-0.055Manufacturable? (Y,N,M) Y Y Y Y Y Y Y Y M Y Y YRock Well Hardness (ISO 2039-2) R80- 114 M89/R122 / M92/R118 M75/R126 / M81 / / R117 R70-90 M81Stiffnes (Youngs Modulus, GPa) 2.21 / 6.9 3 2.2 16.41 3.17 11 / 2-2.7 3.3 0.653Ultimate Tensile Strength (MPa) 40 66 310 59 70 / 86 / 70-75 55 40-69 52Additiona Information: / - No data available

MATERIALS:

Wheel Design

• Balance between a low rolling resistance and stability• Optimum dimensions• Figure 1 shows our first design• Figure 2 shows the second design

[Figure 1] [Figure 2]

Wheel Manufacture

• Accurate manufacture with smooth finish • Consistent surface means minimal

friction• Renishaw offered to allow us to use their

more accurate industry-standard CNC Lathes

The Bearings

• Ceramic over steel bearings• Lighter, higher quality and faster spin• Boca bearings • 2 sets of fully ceramic radial bearing of

dimensions 4 x 10 x 4 (ID x OD x W) mm• Resulting in 80% less friction with a 3 to

10 times longer track life.

The Axles

Material: Weight: Frictional Coefficients:

Density (g/cm3):

Advantages: Disadvantages:

Steel 4.03±0.01g 0.78 7.90 Inexpensive, easily accessible, large supply in school, very strong

High density and therefore weighs a lot, warps easily, ‘Burrs’ created when cutting

Carbon Fibre

3.90±0.10g 0.65 1.80 Lightweight (low density), extremely strong, high tensile and compressive strength, stiff

Expensive, slightly flexible where large force exerted

• Comparison of recommended materials:

• We decided to use carbon fibre. • Saving weight will increase the velocity of

the car.

Finishing the car• Added cellulose sanding sealer to seal the pours in the

Balsa600 grit wet and dry sand paper and fine wire wool to remove and smooth out the finer impurities

• Added a bespoke amethyst base coat to prime the car• Added gold base coat to contrast the purple and to

make the purple pop• Added sparkling purple spray paint as top colouring

layer• Added clear lacquer to protect and maintain the finish

on the car• Sanded the car down with 800 grit sand paper very

lightly between each spray

Simulations

The Wind Tunnel

• Final testing due to take place 31/01/15

Current Rendered Image

Social Media

• Promotion and communication• ‘Pages’ system on Facebook• Allowed for competitions / giveaways• Staying in contact with team members

Running of events

• Arranging of meetings with the headmaster• Head of physics dropping in to observe

progress• Substantial observation and advice from

head of IT Support

• Regular team meetings with recorded minutes• Usage of Gantt chart

Merchandise

• Use of 3D Printer• Key Fobs

• Business cards• NFC

• Branded pens• T-Shirts• Sponsorship

The Pit Display

Quality Assurance / Control

• Constant quality control of each design after finalisation• Worked to regulations with constant oral

feedback

Media / literature

• Vital marketing tools• Organic creation• £4000 saving overall

• Contact and sponsorship• Promotion of sponsors• Solid design philosophy

Identification of sponsors

• Sponsorship is essential for our success• Material and advisory as well as financial• Positive influence to the team• Local knowledge; the internet; family and

friends

Contacting sponsors

• Phone calls and emails• Phone conversations were the most

effective• Direct, memorable conversations

• Able to attain contact details• Further avenues of investigation

• Stayed in contact via meetings• E.g. GE meetings with Alistair Likeman