metals4U are proud sponsors of Team HARE 2019; a group of extremely talented engineering students from The University of Huddersfield.

This week we asked Team HARE to take some time out of their busy schedules to update us on how the suspension team are getting on with their elements of the design and build project.

Each part of the Formula Student race car build must conform to stringent rules regarding construction, material qualities, and health and safety elements. Team HARE have been working hard to fulfil all the criteria to ensure complete compliance to the IMechE rules as the Silverstone static and dynamic testing dates draw closer.  

IMechE regulations for suspension design

Team HARE 2019 suspension team consists of 2 members, Danny Mall and Jack Lynas, they had this to say about how their department has been getting on.

“Our largest development for the year has been our move from 13’’ wheels to 10’’ wheels, saving roughly 15kg of unsprung mass. This has required a full redesign of the suspension system, completely starting from scratch. To design this new system an outside-in method was adopted, choosing tyres and wheels then working inwards through the hub and upright, then wishbones and tie-rods.

The tyre data was analysed to find the optimum working area of our chosen tyre. The suspension geometry was designed through a software called Lotus Shark, allowing for optimisation of the kinematics to maximise the tyres performance. 

The design of the parts was completed through Solidworks CAD package, allowing a full assembly of the system on the car. This has allowed for full integration with the rest of the car, as well as Finite Element Analysis (FEA) of all components to minimise weight and maximise strength.

All suspension members have been constructed using T800H multi directional weave carbon fibre tubing. This gives a total suspension member weight saving of 5.5kg compared to steel equivalents. 7075-T6 aluminium inserts, utilising PTFE lined spherical bearings, have been bonded to the tubes using 3M 9323 epoxy structural adhesive.”

About the team.

Daniel Mall. Suspension Design Manager

Daniel is from Somerset and currently studying towards his MEng in Mechanical Engineering. Daniel has overall responsibility for the design and optimisation of the suspension system. When not busy with Team HARE projects he enjoys wakeboarding, surfing and skateboarding- funnily enough, not sports that include wheels!

Jack Lynas. Suspension Model Manager.

Originally from Essex, Jack’s role within the suspension team is to design the suspension system for the new 10″ wheels. When he is not working hard towards his Automotive and Motorsport Engineering MEng, he likes cycling on both one or two wheeled models, carting, surfing, and like many students- sleeping!

As part of our ongoing sponsorship of Team Hare throughout their Formula Student 2019 season, we caught up with the Electrical and Control Systems Integration department to see how their elements of the team build are going.

The electrical and controls systems integrations are a physical interconnection of devices that impact the performance and operation of other systems and devices within the car build.The Formula Student rules for the 2019 season are devised and implemented by IMechE- the rules run to very tight specifications so the role of the Electrical Systems Designer is to ensure that all the restrictions and specs are strictly adhered to ensure safety, while also endeavouring to optimise performance.

It has been very busy for Team Hare this year and the design and build of the electrical system has been compromised due to changes in the powertrain and body system. The main priority of the electrical department is to offer reliability and durability while the car competes in several dynamic events in the United Kingdom and across Europe. Dedication and commitment are required during the project to meet the planned dates for engine testing and control systems functionality, whilst working concurrently with the other departments.

Here is a quick insight into the responsibilities of the electrical and control systems team.

The electrical and control systems integration department consists of one BEng Student, Panagiotis Kyriakou.

Panagiotis Kyriakou. Electrical Systems Designer

Panagiotis Kyriakou is originally from Deryneia, Cyprus; he is solely responsible for the integration of electrical and control systems, including the dyno and chassis loom design. Currently studying for his BEng Automotive and Motorsport Engineering, he also likes to learn about cutting edge technologies in his free time.

As Gold Tier Sponsors of Team HARE-19 from the University of Huddersfield, we took the opportunity to catch up with the chassis construction team to see how they are getting on as the Formula Student 2019 competition rapidly approaches ‘crunch’ time.

The Chassis department comprises of two MEng students, Filip Sieminski and Jamie Mistry.

The main focus of Filip’s development is to design and manufacture a tubular cold drawn steel spaceframe chassis. The main challenge of this year’s spaceframe design was to accompany the newly applied 10-inch wheel geometry. A target for the design was to allow the vehicle to be easily maintained with the design philosophy of applying a mainframe and sub-frame system. The sub-frame houses the engine, drivetrain assembly and the rear suspension, this is to allow easy maintenance and service of the engine whilst at events. To produce the spaceframe, the method of using TIG welded technology has been utilised.

Jamie’s focus this year has been on redesigning and manufacturing the braking system, including the pedal box assembly with the aim to be easily maintained, adjustable, lightweight and ergonomic. The braking system consists of newly designed laser cut brake discs and braided lines to enable exceptional braking force which provides superb driver feedback, whilst also reducing rotational mass (Inertia). The braking system is really crucial to the HARE-19 vehicle build, as a minimal stopping distance will decrease lap times and give the team a competitive edge over opponents. This is achieved through reducing the un-sprung mass and optimising the design by conducting computational simulation analysis and testing.

Filip Sieminski- Chassis Construction Team Leader.

Filip Sieminski is working towards his Automotive and Motorsport Engineering MEng at Huddersfield. Originally form Poland, Filip has maximised the opportunities that studying in Huddersfield has to offer- when not working incredibly hard as the Chassis Construction Team Leader, he likes to eat, sleep, and party. Filip is particularly proud of the fact he has completed all the ‘eating challenges’ in Huddersfield.

Jamie Mistry. Chassis Construction Team Manager.

Jamie is studying for his Mechanical Engineering MEng. From Halifax, Jamie is proudly the only northerner on the team this year. When not designing the pedal box and braking system for the Formula Student car, he enjoys motorcycling, travel, and participating in a variety of sports.

If you are embarking on a motorsport project and are in need of EN 10305-1 specification mild steel tube or BS4 T45 grade steel tube, check out our online store, or call our friendly and knowledgeable customer services advisors to find out more, or place an order.

Until the end of May, our T45 tube is discounted by a massive 30%- so grab yourself a bargain and don’t forget, we offer free delivery on all orders over £75.

Offer valid until Friday May 31st 2019.

As you  probably already know, metals4U are sponsoring the Formula Student team from the University of Huddersfield for this racing season. We are delighted to be able to put our name to this amazing endeavour. The team of young men and women are working around the clock to ensure that every element of this year’s car is performing to the highest standard.

Last week, Team Hare revealed the new chassis design for the competition, here is the CAD presentation to give you an idea of what the final build will look like.

The Team Hare entry for 2019

Now we can see what the final build will look like, we can start to appreciate just how much work has already been done this season.

The design of the aero package (front and rear wings, nose cone,sidepods, floor diffuser and bodywork) is not just to look good, every single element has to ensure that the car is subjected to minimal drag and maximum streamlining for optimal performance…Think bullet rather than parachute!

The aerodynamics team have been busy during the planning stage to see how they can work with the drag and lift forces that are created when air passes around and over an item- particularly when that item is travelling at speed- they need to be able to create a perfect balance of keeping the car securely on the road, while minimising the drag forces that will slow it down unnecessarily or create instability.

Due to the costings of the bodywork construction and not having a full size wind tunnel, Team Hare have come up with a solution to testing the aerodynamic performance without creating a full size body kit. ‘Experimental Designs’ have 3D printed a 10th scale model of the aero package to enable Team Hare to test in the windtunnel to ensure their CFD (Computational fluid dynamics) predictions are accurate before investing in the full size, and full cost, componants.

This week we caught up with the aerodynamics team led by Charlie May and Rafael Doherty to see how they were getting on, they had this update for us;

“The Aerodynamics department has focused on ease of manufacturability this year whilst also ensuring a beneficial aerodynamic performance package is created.  Due to struggles within the manufacturing of aerodynamic components in recent years, simplified yet effective designs have been implemented.  A huge amount of work has been spent tweaking aerofoil angles and analysing airflows over the vehicle to ensure each component is as effective as possible, and this simplified approach has allowed the aerodynamics department to work towards the ‘Aero on a budget’ award at Formula Student Silverstone, with the front wing, sidepods, rear wing, nose cone, bodywork, and floor diffuser all aiming to be manufactured for under £1800. With materials beginning to be delivered, it’s time to get our hands dirty and get building ready for the new HARE-19 vehicle.”

Charlie May. Aerodynamics and Bodywork Leader.

Charlie is the Aerodynamics and Bodywork Team leader. Currently studying for his Automotive and Motorsport Engineering MEng, he is responsible for the design of the aero package, the manufacture of the bodywork, and composite material elements of the vehicle build.

Rafael Doherty. Deputy Aerodynamics Manager

Rafael is an exchange student from Brazil studying at the University of Hudderfield for 6 months as he works  towards his Mechanical Engineering MEng. Rafael is reponsible for designing the front wing, nose and the rear wing using CAD and CFD analysis.

This year’s gold tier sponsorship of Team HARE is one of the really exciting endeavours of our 2019 pledge to continue our support of innovation and emerging talent in engineering.

Team Hare are continuing to work tirelessly towards creating their best performing Formula Student car for the 2019 season. This week we caught up with the team to see how they are progressing.

Last time we caught up with Team Hare, we looked a little closer at the drivetrain- if you missed it, you can read all about it  here.

This week we caught up with the ‘Powertrain’ team to find out how they are getting on.They had this to say;

“The main aim for the department this year is to have the engine operating reliably whilst producing a high power output. With the teams major changes to the chassis and suspension, there has also been a lot of work with regards to redesigning a new exhaust, lubrication and fueling systems. A huge amount of hours have been spent dyno testing the engine, this assists us with ensuring we will have reliability throughout 2019’s formula student events through correcting and improving the current engine build.  An exciting few months are now ahead of us, as parts of the car start to arrive and we get to see how well our engine performs in the newly designed car.”

The powertrain is the system that transfers the drive from the engine right through to the axles. Whereas the drivetrain is concerned with the drive from the transmission onwards, the powertrain is concerned with all the parts that convert the engine’s power to movement- all elements of propelling the vehicle.

The performance of the engine has to harness the power of combustion to deliver energy to the crankshaft- here the linear motion energy is converted into a rotary motion known as ‘torque’. This torque is then controlled by the transmission system, which then passes the energy onwards through the remainder of the powertrain that is comprised of the drivetrain elements.

A simplified explanation of the powertrain.

The powertrain team is led by Conor and Jack, they are responsible for ensuring everything runs smoothly and on time within their team.

Conor O’Brien. Powertrain Team Leader

Conor O’Brien is the Powertrain Team Leader with overall responsibility for the management of the engineering of the powertrain and the rest of the team. Conor is currently studying for his Automotive and Motorsport Engineering MEng and hopes to pursue a career in motorsport once he completes his Masters- he is certainly off to a good start.

Jack Watson. Powertrain Team Manager

Jack Watson is also studying for his Automotive and Motorsport Engineering MEng and is sharing leadership of developing the powertrain. Jack’s role specifically sees him working on engine mapping and intake and exhaust design.

To keep up to date on our sponsorship activity, follow us on social media!

Formula Student season is now in full swing, and as part of our ongoing support of student talent we are pleased to be able to add the University of Leeds Formula Student team to our portfolio of sponsorships for the 2019 season.

We are very excited that steel and aluminium (sheet and tube)  supplied by metals4U has been used throughout their vehicle design this year.

Welded frame of the 2019 Formula Student entry from the University of Leeds.

This year the team are competing in two events; the annual UK event at Silverstone (17th
-21st July 2019) and, for the first time,  an event in Italy (24th-28th July 2019).

The project is led by third year mechanical engineering student, Julian Kautsch, who is overseeing the team efforts and targets for the FS19  season which are outlined below ;

• To finish in the top 10 at the UK competition
• To finish construction by the end of March
• To compete in a competition abroad
• To do a minimum of 500km of testing prior to competition
• To create stable foundations which next year’s team can build upon

A couple of these goals are already in sight as the construction of this year’s vehicle build is 3 months ahead when compared to last year’s progress and they are already set to compete in Europe.

Months of planning, testing, and incredibly hard work are now coming to fruition as the team prepare for the demands of the gruelling challenges of static and dynamic testing, these tasks are set to showcase the very best in engineering acheivements for this year’s student entrants.

The University of Leeds Formula Student team had these kind words to say about our sponsorship;

” We are extremely grateful to have formed a sponsorship deal with metals4U who have kindly
provided us with a range of metal tubing and sheeting which will be utilised across our vehicle. For
example, the aluminium tubing is going to be used inside the wings, the steel tubing for rear wing
mounting and the aluminium sheeting for the undertray and body panels.”

metals4U steel tubing used for rear wing mounting (shown in red)

We look forward to following the progress of the team- to keep up to date with all things Formula Student, follow us on social media!

This week we caught up with Team Hare 19  to see how things are taking shape this season, and in particular what the drivetrain team are working on at the moment- Team HARE’s drivetrain team are responsible for the configuration of the drive method between the engine and wheels, as well as the gear shifting method. They had this to say,

“This year’s aim for the drivetrain team is to ensure an efficient and reliable gear shifting method. Decision was made to utilise a mechanically hand activated gear shifter as this would drastically reduce overall weight and packaging. Current focus is made to maximise feel in the gear shifter. Numerous components have been designed to ensure minimum deflection of the push pull cable when it is in motion.”

The drivetrain is not a part of the engine, it is the system of component parts from the transmission to the wheels- the system of transferring the power from transmissionright through to the clutch, gears and differential to the axles and wheels; basically, everything beyond the transmission concerned with propelling the car forward!

A simplified explanation of the drivetrain.

As part of our sponsorship of Team Hare, this week we would like to showcase two members of Team Hare with overall responsibility for the drivetrain.

Ben Tripp. Drivetrain Team Leader

 As the Drivetrain Team Leader, Ben Tripp has overall responsibility for ensuring everything within the drivetrain system works and oversees the rest of the drivetrain team.

Ben  is a student from Cambridge currently on the Mechanical Engineering MEng course at the University of Huddersfield.

Stefanos Savva. Drivetrain Team Manager

As the Drivetrain Team Manager, Stephanos Savva has responsibility for ensuring the drivetrain parts are in optimum working condition and replacing or repairing parts if modifications are necessary.

Stephanos  is also studying for his Mechanical Engineering MEng at the University of Huddersfield.

Don’t forget to follow us on social media to keep up to date with our sponsorship of Team Hare 19!