DynamicΣ PRC: production of a composite material aerodynamic package

From June Issue of Compositi Magazine

Jacopo Muzio – Press Office DynamiΣ PRC

How can an aerodynamic profile be translated from a tridimensional computer designed model to a component ready for assembly? Today, DynamiΣ PRC engineers are going to explain us

DynamiΣ PRC, racing department of Politecnico di Milano, was born in 2004 on the initiative of the Mechanical Systems Engineering Department, that have made available for some students a place to be used as lab and workshop to realize the first University’s Formula SAE prototype.

After some development years, the students still in the project decided to refound the team, setting it up with a business approach. This, results in the subdivision of the Team in departments, with the assignment of clear managerial roles, and an increase of the participants number from fifteen to sixty, up to a hundred thirty during the last seasons, selected after an accurate
evaluation process.

The new general organization and the subdivision of the different tasks, allow DynamiΣ PRC to renovate every year the prototype, that is enriched step by step with several cutting- edge technical solutions like the carbon fiber monocoque, the data acquisition system, the usage of aerodynamic appendages on the sidepods and an always more relevant usage of composite materials.

Last developement regards the change of category from Combustion Vehicle to Electric Vehicle during the 2019/2020 season. During the 2016 season, the ultimate breakthrough was reached, when the Aerodynamic Department designed and realized the first complete package, using mainly composites reinforced with carbon fiber.

It was equipped with front and rear wings and lateral sidepods, accessorized with flaps to generate more downforce, that is vertical load, that allows a better grip in the turns. Since this, the development of the aerodynamic package has inserted new and always more light appendages related to the generated downforce, thanks to the usage of new structural simulation techniques and to the choice of always better raw materials and manufacturing processes.

One of the most important aspects connected with the production of an aerodynamic package is the correspondence between the CAD designed model and the final component. It is fundamental to perfectly replicate the surfaces of main wing profiles, flaps, suports and turning vanes, so that, when they are assembled all together, they work as desired. Variations in the curvature, in the chord length, in the camber and of the camber line generate unwanted effects.

An example

Mistakes in the production of the principal front wing shapes, that create a condition of flow difference form that one that was simulated, could makes useless all the studied done on the flaps that are behind it. Working in a wrong flowcondition in confront of the forecasted one, the flaps would be inefficient.

Between 2016 and today, the DynamiΣ PRC engineers have experienced several manufacturing processes to produce aerodynamic components that, on the base of the situation, they need or the realization of a model or they go directly to the production of a mold. This choice is influenced by various factors, some examples can be the:

  • dimensions of the component
  • deformation risk during curing phase
  • need of a perfect finishing or in both upper and lower surfaces, like for profiles and laps, or on only one surface, like in the case of the floor, and then for requirements due the extraction of the component from the mold.





Leggi anche

CRP Technology has built the supporting structure in a single part: sole, midsole, nails, and ribs. The result is an innovative functional prototype for customization, technologies and materials used. The Windform SP has made it possible to create a special spiked shoe for the track with high elastic properties and resistance to deformation even in thin thicknesses….

Leggi tutto…

BCN3D, a Spanish leading 3D printing solutions manufacturer, announced the launch of the new Smart Cabinet to complete the Epsilon ecosystem. The Smart Cabinet relies on smart drying technology to ensure that filaments are consistently kept at optimal humidity levels, guaranteeing the best results in every print job and protecting against print failure and nozzle clogging. This project is one of the winners of our first Call for Papers, read it! …

Leggi tutto…

The growing demand of Carbon Fiber Reinforced Polymers (CFRPs) raises some issues related to the relevant environmental impacts of their manufacturing processes. Recycling is not always an available or convenient option! A possible solution has been proposed within the CIRCE EU LIFE project, developed as a collaboration between five Italian companies: HP Composites, Alci, Base Protection, CETMA, and Petroceramics. Read the full article: this project is one of the winners of our first Call for Papers!…

Leggi tutto…

In un mercato in rapida evoluzione, offriamo soluzioni che non solo garantiscono la qualità dei prodotti finali ma che sono anche in grado di rispondere in maniera efficiente alle esigenze e ai bisogni di ogni singolo cliente. Rivolgendosi alla nostra azienda, ogni cliente sa di poter ottenere esattamente ciò che vuole con la certezza di ottenere qualcosa di unico….

Leggi tutto…

Together with GKN Aerospace Deutschland GmbH, TUM – Chair of Carbon Composites, SGL Carbon, Augsburg University of Applied Sciences, and under the co-founding authority of Bavarian Ministry of Economic Affairs, Regional Development and Energy, Cevotec started a pioneering R&D project: the full automation of sandwich structure production. …

Leggi tutto…