Leeds Formula Race Team Newsletter

November Edition

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Team Leader Message

This month has been packed with decisions for the team moving forward by changing to 10 inch wheels and tyres, whilst additionally looking to be the first Leeds team to run with an aero package. After attending learn to win at the Institute of Mechanical Engineers (IMechE), the team have produced its aims for the coming year: 1. Design & Manufacture, as a team, a reliable car which is competitive in all competition events. 2. 5% improvement in all areas (weight, acceleration, etc) 3. Regular test sessions to develop the car throughout the year. 4. First Leeds Formula Race Team to include a complete aerodynamic package. 5. Finish in the top 10 UK universities at FSUK. These will help the team to remember the aim throughout the design and manufacturing process. In order to meet these objectives, this year’s team will have set a first in Leeds Formula Race Team’s history by setting dates for a design review and freeze process, whereby the design stage is stopped in early 2015 to allow adequate time for manufacture and an early test scheme. This year is shaping up to be very exciting for Leeds Formula Race Team with an emphasis put on stepping up a level in regards to the competition and professionalism in the team. Looking towards the future of the team, a mentor system has been implemented to involve lower years in the most exciting aspect of automotive engineering!

Scott Walker, Team Leader

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Aerodynamic Package

2015 will be the first year that Leeds Formula Race Team will compete with a full wing package. Team aerodynamicist, Ioannis Mandroukas, has designed and analysed two configurations, with front and rear wings, before presenting the results to the team. The investigation covered a wide spectrum of benefits gained as well any drawbacks involved. Besides performance, other important parameters such as weight, cost and manufacturing were discussed. Firstly, a baseline aerodynamic analysis of last year’s car was conducted to draw comparisons. Design flaws, especially the diffuser geometry, were identified and results showed net lift for the overall car. The first wing configuration used high lift, high camber aerofoils, comprising of a two-element front wing and three-element rear wing with relatively medium chord length. Results showed adequate amount of lift, but from the flow visualisation observation the angles of attack appeared to be excessive. Iteratively a second configuration was designed which used the same high-lift aerofoil profiles but with increased chord and angles of attack. This doubled the overall lift, reaching lift forces produced by the top 5 universities of the competition and showed a 412% increase in lift to drag ratio compared to the F15 wingless baseline. Various manufacturing processes were reviewed, leaving carbon fibre as the optimum material to use because of its high strength and low weight. The maximum weight of the overall wing package along with the mounting parts was estimated to be 15-20kg. The wings are going to be manufactured in house with a double mould, carbon fibre pre-preg method and the overall cost for materials is roughly estimated to be between £600-800. At the moment the new rules which restrict the aerodynamic devices are being reviewed and different aerofoil profiles are being tested. The key changing parameters tested are the maximum thickness and camber location, leading edge radius, ground clearance, angle of attack, number of flaps and flaps x,y spacing. The wing designs are expected to be finished by February, when manufacturing will begin.

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Visit to MAHLE Powertrain

On the 20th October, we paid a visit to our main sponsor for the 2015 season, MAHLE powertrain. Leeds Formula Race Team’s Engine division hopes to make use of MAHLE’s experience and facilities in Northampton to expand development of the team’s new KTM 510 engine. As well as the six members of the Engine team, the other respective team leaders headed to Northampton to discuss aims for the coming season and how MAHLE could assist the team. The team were provided with a tour of the impressive engine development facilities to show how this can be achieved over the coming months. The team hopes to gain guidance in building a detailed GT Power software model of the engine with MAHLE’s senior engineers to improve the power output and efficiency of the engine. This model can then be verified by running our development car, F15, on their chassis dyno, accelerating development in a key area of the vehicle. Previously engine development has been reliant on construction of a new chassis, whereas this year the engine team can get a model created well in advance of competition as a result of our partnership with MAHLE. We would like to take this opportunity to thank Simon Williams and Mark Stephenson for showing us round and providing support for this years team.

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Engine Model Scan at SIMPACT This month two members of the team took the engine for a visit to SIMPACT Engineering in Warwick. The purpose of the visit was to reverse engineer our new KTM engine into a workable CAD model to aid the team whilst designing the F16 chassis. The trip involved using a laser scanner, and then post processing the data to build up a model. The team members were required to learn new software as well as deal with the challenges of a complex shape such as an engine. The trip was a great success and we would like to thank Tim Williams for his help and guidance to complete the project. The final model has been successfully utilised by the team and is shown below along with other pictures of the engines big day out.

Learn to Win at the IMechE

On Halloween, 10 members of the team attended the institute of mechanical engineers (IMechE) learn to win event in London. Over 25 of this years participating UK teams attended the event at the IMechE's headquarters to gain an insight into this years competition. The morning session was broken into a series of lectures to discuss competition process, before the afternoon was plot into individual roaming to meet judges.

The morning session gave a full breakdown of points for the aspects of competition, emphasising the importance of a reliable and well tested car to succeeding at competition. Additionally the opportunity to apply for IMechE grants towards aiding the team was presented, something Leeds Formula Race Team hopes to make use of.

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Learn to Win at the IMechE continued

In the afternoon, we had the opportunities to speak to a number of judges at this years competition. Industry experts and experienced judges offered advice ranging from business presentation aspects to composite manufacture of wings. Former Leeds Formula Race Team member, Howard Ash (F1-F5), was on hand to offer advice in his current judging capacity, suggesting a wheel supplier for our new 10 inch wheels.

Overall, the learn to win event was an invaluable experience. The advice for business presentation and cost report was of particular bonus due to the lack of expertise in the team. There is now a clear direction to take the business side of the competition into, something that will be included in more depth in future newsletters.

A new addition to the structure of the Leeds Formula Race Team is the mentoring scheme to ensure smooth transfer of knowledge to subsequent teams. Each core team member is assigned lower level students who are keen to get involved with the team. The scheme was introduced as a result of the lack of structure in past years get lower levels involved. This was a frustration to many of the current team members, as this would have helped the transition into this year. The Scheme is an opportunity to develop the talent of lower level students so that they are in a better position when they step up to being a core team member. This ensures that each formula student car that the University of Leeds enters in the competition going forward has taken into account the lessons learnt from previous year’s cars rather than starting a fresh each year. It helps align the team with the same methodology that professional race teams use today, increasing the professional output of Leeds Formula Race Team.

Mentoring Scheme

Thanks for your continued support

Leeds Formula Race Team

Mechanical Engineering

Woodhouse Lane

LS2 9JT

leedsformularaceteam@gmail.com

@leedsFSAE

/LeedsFormulaStudent