Haroon Usman's DFM Professional Report

CITY OF GLASGOW COLLEGE

Alloy Wheel Design Project

DR3M 35 – Design For Manufacture

Team Members:

Haroon Usman Saraj Salihmurad

Daniel Smith Kirpal Singh

Lecturer: David Gorrell

Haroon Usman

N10147400

Submission Date: 01/03/16

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Comment / Feedback:

Student Signature : .................................................................... Date..................................

Signature of Lecturer : .............................................................. Date...................................

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Table of Contents 1. Customer Requirements ..................................................................................................................... 4

2. Design Specification ............................................................................................................................ 5

2.1 Performance ................................................................................................................................. 5

2.2 Safety Considerations ................................................................................................................... 5

2.3 Budget Costs ................................................................................................................................. 5

2.4 Product Life Span .......................................................................................................................... 5

2.6 Manufacturing Standards ............................................................................................................. 5

2.7 Aesthetics ...................................................................................................................................... 6

2.5 Environment .................................................................................................................................. 6

2.8 Ergonomic Factors ........................................................................................................................ 6

2.9 Surface Finish ................................................................................................................................ 6

2.10 Dimensional Requirements ......................................................................................................... 6

2.11 Drawings/Tolerances .................................................................................................................. 6

2.12 Documentation ........................................................................................................................... 6

3. Project Schedule ................................................................................................................................. 7

4. Current Designs ................................................................................................................................... 8

4.1 TSW ............................................................................................................................................... 8

4.2 Wolfrace ........................................................................................................................................ 9

5. Manufacturing Considerations ......................................................................................................... 10

5.1. Aluminium .............................................................................................................................. 10

5.2. Titanium Grade 5 ................................................................................................................... 11

5.3. Carbon Fibre ........................................................................................................................... 12

6. Manufacturing Processes .................................................................................................................. 13

6.1. Titanium Manufacturing Process ............................................................................................... 13

6.1.1. Extraction ............................................................................................................................ 13

6.1.2. Purification .......................................................................................................................... 13

6.1.3. Sponge Production .............................................................................................................. 13

6.1.4. Alloy Creation ...................................................................................................................... 13

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6.2. Aluminium Manufacturing Process ............................................................................................ 14

6.2.1. Sand-Casting........................................................................................................................ 14

6.2.2. Low-pressure Die Casting .................................................................................................... 14

6.2.3. High-pressure Die Casting ................................................................................................... 14

6.2.4. Aluminium Gravity Casting.................................................................................................. 14

6.3. Carbon Fibre Manufacturing Process ........................................................................................ 15

6.3.1. Spinning ............................................................................................................................... 15

6.3.2. Oxidation ............................................................................................................................. 15

6.3.3. Carbonisation ...................................................................................................................... 15

6.3.4. Surface treatment and sizing .............................................................................................. 15

7. Standardisation and rationalisation .................................................................................................. 16

8. Resource Availability ......................................................................................................................... 16

9. Simulation ......................................................................................................................................... 17

10. Modelling ........................................................................................................................................ 18

11. Details of Final Design ..................................................................................................................... 18

12. Benefits of a Team Approach .......................................................................................................... 19

13. Evaluation of the Design Process .................................................................................................... 19

14. Appendix ......................................................................................................................................... 20

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1. Customer Requirements The design team at Scottish Alloys Ltd are based in Scotland. Established since

2007 and we design alloy wheels for any type of car from a hatchback to a sports

car.

Ferrari have approached and contacted us to design a set of 4 alloy wheels for their

brand new car called The 448 Spider to which we have been given a timeframe of 6

weeks. We have discussed on how many prototypes should be made and we have

come to an agreement that one prototype will be produced to test out at

Silverstone.

Ferrari are an Italian Sports car Manufacturer in which their headquarters are in

Maranello, Italy. The company was founded in the 1930s by a motor racing driver

and entrepreneur called Enzo Ferrari. They manufactured there first car in 1940 and

in 1947, the company designed their first Ferrari-badged car was complete to which

makes them the automotive manufacturer that they are today.

They have given a budget of £500,000 to which we must present to them with one

final design using Titanium, Carbon Fibre or Aluminium and reason behind the one

which has been chosen.

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2. Design Specification

2.1 Performance

Our alloy wheel has to withstand the weight of the car, not sheer under

acceleration and breaking and finally it has to look aesthetically pleasing. It

must withstand the maximum power of V8 engine which is 670 horsepower at

8000rpm and its acceleration from 0 to 100 km/hr in 3 seconds flat out and

from 0 to 200 km/hr in 8.7 seconds

2.2 Safety Considerations

ISO 7141 Standard.

UK Health and Safety Act 1974.

All employees must be wearing PPE when manufacturing the alloy wheel.

Control of Substances Hazardous to Health Regulations 2002 (COSHH).

Supply of Machinery (Safety) Regulations 2008.

Equipment and Protective Systems Intended for Use in Potentially Explosive

Atmospheres Regulations 1996.

2.3 Budget Costs

One prototype will be produced to go under various tests to find any failures

with this prototype to produce a final design of the product, this will cost

£100,000.

Each member of the team will be paid £100 per hour and this will include:

Pensions, National Insurance, Public Liability, Overheads which will be

divided between the team and Profits.

The full built and testing will be cost £25,000.

Materials will cost £250,000.

A set of four will cost £1,500.

2.4 Product Life Span

The product will have a life span of 50 years with proper maintenance.

2.6 Manufacturing Standards

These 18” alloys will be made from a choice of Carbon Fibre, Aluminium and

Titanium. This must contribute to better fuel efficiency as well as better

handling, accelerating and breaking.

When manufacturing alloy wheels, it undergoes various processes including

casting, forging and sheet metal process. During the final finishing operations,

it undergoes, painting, varnishing, polished followed by a clear coating and

finally a chrome wheel finish.

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2.7 Aesthetics

Main colours for an alloy wheel is grey same on supercars and a daily car.

The standard size of an alloy wheel on Ferrari is R18 or R19 and has 5 holes

in it.

The alloy will be made from both aluminium and magnesium alloy wheels.

2.5 Environment

This car will be expected to function on all types of roads and have the ability

to adapt to the climate/weather changes in each country as it’s to be sold

globally.

2.8 Ergonomic Factors

The weight and design of the wheels must be taken into consideration when

designing the alloy. Not taking those factors into consideration will likely result

in ‘sub-standard’ alloys.

2.9 Surface Finish

The alloy wheels will be coated and sprayed with silver paint first then

polished to give it the finish.

2.10 Dimensional Requirements

The alloy will be 18 inches in diameter as well as including rim size, width size

etc. This will also include tolerances on sizes such as rim size to be

considered when in the manufacturing process.

2.11 Drawings/Tolerances

Three concept drawing will be produce and the final design will be one

drawing and will be produced during the timeframe in a 3D model using

AutoDesk Inventor.

2.12 Documentation

User Manual

Repair Insurance

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3. Project Schedule

The team’s project schedule states the all key important days of the schedule which

are listed below (See Appendix 1):

The research of the project; 26/2/16 – 2/2/16

Construct Concept Designs for the product; 2/2/16 – 9/2/16

Produce a final fully detail drawing on Autodesk Inventor; 9/2/16 – 23/2/16

Plan and practice the presentation for the client; 1/3/16 – 7/3/16

Present the design of the product to the client; 8/3/16

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4. Current Designs

This section will include the team’s research on the particular designs for Ferrari

sports car alloy wheels which are on the market right now and are available for

purchase from the competition. The research below gives information on each

supplier and the alloy wheel they supply for Ferrari giving the properties as well as

pros and cons about the product.

4.1 TSW

Back in the 1960s, a Former Formula One Racing

Driver called Eddie Keizan created a company called

Tiger Sports Wheels. The company only had a small

manufacturing facility at the time and were located in

South Africa.

The company are known now as TSW and are one of the

longest serving alloy wheels suppliers to date. With production

of the alloy wheels now commencing in the likes of Germany,

Poland and the US.

Properties Advantages Disadvantages

Rim Size 18” Long-lasting.

Aesthesis

are pleasing.

Costing for

Manufacturin

g are

expensive

due to the

technology

needed to be

up-to-date to

manufacture

Titanium.

Width Size 8”

Pitch

Circle

Diameter

(PCD)

5x112

Material Titanium

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4.2 Wolfrace

Wolfrace is one of Britain’s popular alloy wheel suppliers and

have been formed since the 1970s.

With their head office in Essex, they have a wide range of

designs for alloy wheels in which are cheaper to buy and have

high quality than any other supplier. If a set of alloy wheel is

sold from this company, they provide a guarantee of five years

after TUV approval if anything goes wrong with their products.

Properties Advantages Disadvantages

Rim Size 18” Material is

affordable

Easy to

manufacture

Does weight

as much

Needs to

be

constantly

maintained

Width Size 9.5”

Pitch

Circle

Diameter

(PCD)

5x114

Material Polar

Silver

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5. Manufacturing Considerations The design team have agreed with the client that the alloy wheels could be made

from Aluminium, Carbon Fibre or Titanium. Below shows the research gathered by

the team and the characteristics of each material.

5.1. Aluminium

Aluminium is often used as an option for manufacturing an alloy wheel due to the

fact of its properties and that it is very popular when it comes to the everyday cars.

However, it does have its drawbacks. Here are the advantages and disadvantages of

this material.

5.1.1. Advantages of Aluminium

Provides the product with a high quality surface finish

Allows the car to use less fuel in which less CO2 is produced and emissions.

Does weight as much.

No damage occurs to the material.

Withstands electrical and thermal effects on the material.

5.1.2. Disadvantages of Aluminium

Relatively hard to buy due to the fact it is overpriced.

Can easily be broken due to it having a low young modulus value.

It’s not very tough and can easily get scratched.

5.1.3. Properties of Aluminium

Properties Material Data

Density (kg/m) 2823

UTS (N/m) 240-590

Elongation at Break (%) 8-9

Yield strength (N/m) 120-540

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5.2. Titanium Grade 5

Titanium alloy wheels are mainly manufactured using grade 5. The material is made

of a mix of 6% Aluminium, 4% Vanadium and 0.25% Iron. On the other hand, it has a

number of disadvantages. Here are the advantages and disadvantages of this

material along with the properties:

5.2.1. Advantages of Titanium Grade 5

No damage occurs to the material.

Hard to break.

Durable.

5.2.2. Disadvantages of Titanium Grade 5

Relatively hard to buy due to the fact that it is much overpriced.

Hard to renew compared to Steel.

Manufacturing costs are relatively high due to the casting process.

5.2.3. Properties of Titanium Grade 5

Properties Material Data

Density (kg/m) 4420

UTS (N/m) 897

Elongation at Break (%) 10

Yield strength (N/m) 900

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5.3. Carbon Fibre

This material is largely popular chosen for sport cars in general. They manufactured

for your typical sports cars for their body work, interior and alloy wheels. Compared

with all three materials, this is the lightest out of them all. But it is relatively expensive

for manufacturing an alloy wheel. Here are the advantages and disadvantages of this

material along with the properties:

5.3.1. Advantages of Carbon Fibre

It is hard to break due to it being stiff.

Excellent strength to weight ratio.

Doesn’t get affected by temperature.

No damage occurs to the material.

One of the lightest materials in the market.

5.3.2. Disadvantages of Carbon Fibre

Relative expensive to buy.

It’s hard to fix if it becomes damaged.

Sensitive to sudden impact or blast.

5.3.3. Properties of Carbon Fibre

Properties Material Data

Density (kg/m) 25.5

UTS (N/m) 1000

Elongation at Break (%) 1.5

Yield strength (N/m 2900

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6. Manufacturing Processes

6.1. Titanium Manufacturing Process

Manufacturing a block of Titanium into an alloy wheel is done so by a process call

Kroll which involves six different steps which are: Extraction, Purification, Sponge

Production, alloy creation, forming and shaping. Details on how it is processed are

described below:

6.1.1. Extraction

Titanium goes into the process of taking out the iron from the metal to which

only 85% of Titanium Oxide remains. The metal is then put into a reactor and

is mixed with Chlorine Gas and Carbon in which it is heated up to 900°C

6.1.2. Purification

After the extraction process has occurred, the metal is placed into a distillation

tank in which goes into the process of separating substances by a process

can distillation. After this has been done, it is heated up via precipitation

process and results in purified Titanium Tetrachloride being formed in a liquid

state.

6.1.3. Sponge Production

The liquid is then moved into a reactor vessel in which is reacts with

Magnesium and heated up to just over 1,000°C. After this reaction has

happened, different chemicals are added to cleanse the solution to which the

final produce is a pure Titanium Sponge.

6.1.4. Alloy Creation

This resulting product is put into a heater along with different types of metal

which are spare to use and results in an alloy being produced. The alloy

wheel is then shaped, welded and milled in the particular shape to which an

alloy wheel is created.

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6.2. Aluminium Manufacturing Process

Manufacturing a block of Aluminium into an alloy wheel is done so by two processes

which are known as Ingot Casting and Mould Casting. Mould Casting split into two

different casting process which are sand-casting and die-casing. Details on how it is

processed are described below:

6.2.1. Sand-Casting

The aluminium is heated up into which it is melted and is turned into a mould

of sand and goes into the die-casting process in which it manufactured at both

low pressure and high pressure.

6.2.2. Low-pressure Die Casting

A pot pressured at approximately 0.7 bar is filled with die where the mould

goes into the pot and thickness the materials wall.

6.2.3. High-pressure Die Casting

This is where the aluminium mould goes under high pressure and goes

through the process of casting. This is done by a piston which applies

pressure at high velocity to the mould.

6.2.4. Aluminium Gravity Casting

After the mould has gone through high pressure casting, it is then cast

through gravity by a gravity casting machine which is either done by the

mechanically or by hand where it would be milled and forged into the design

chosen by the team for the alloy wheel.

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6.3. Carbon Fibre Manufacturing Process

There are various steps in manufacturing a carbon fibre which are; spinning,

oxidation, carbonisation and finally surface treatment and sizing. Below describes

each step in how it is manufactured.

6.3.1. Spinning

A plastic concentrate called Acrylonitrile reacts with another plastic with a

catalyst added to speed the process up in which a plastic is formed as the

product of this reaction.

The plastic is then turned into fibres by a process where it placed into a

chemical bath by whirled around. This increases the viscosity of the plastic

which then turns it into a solid form.

The fibres are cleaned by washing it and are stretched to the required

diameter needed and spun into the shape of the alloy wheel.

6.3.2. Oxidation

This process involved a furnace where an oxidation reaction occurs to where

the fibres are heated up and reacts with oxygen.

6.3.3. Carbonisation

This step in the manufacturing process removes any particles which are not

carbon and breaks the bonds with carbon which is then turned into a

crystalline structure.

6.3.4. Surface treatment and sizing

This is the main manufacturing process where the shape of the alloy wheel is

manufacturing according to the design determined by the team.

The fibres change its surface by a process called electrolysis to which it is

then shaped in the design produced by the team by considering the diameters

and tolerances requirements of the alloy wheel.

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7. Standardisation and rationalisation Standardisation may affect our design due to the Pitch Circle Diameter which is part of the design. In addition, it may affect the tolerance, diameter and length of the nuts and bolts in which are used. However, Ferrari has agreed with the team on the dimensional requirements such as Pitch Circle Diameter to allow the bolts to fit the wheel and the brake discs. They will supply the nuts and bolts which will be standardised and made it easier for their customers to replace if needed. Rationalisation may impact the design due to the size of the brake discs and the size of the caliper for the braking system. However, Ferrari has agreed the dimensional requirements and tolerances with the design team so that the alloy wheel attaches to the wheel studs and the dust cap of the brake discs.

8. Resource Availability The design team have decided that the alloy wheel will be manufacturing using

Carbon Fibre. This material is readily available for the team because they have

contacted a supplier based in the UK who will supply them the amount of Carbon

Fibre needed and will give it to them at a cheaper price than any other supplier

across the UK and the world. This means of course that it is cheaper to afford and

within the team’s budget as well as easily delivered with no problem occurring. In

addition to this, the nuts and bolts for the alloy wheel will be supplied by the client

and will be standardised.

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9. Simulation The design team have come up with three different concepts based on the research

done which will suit the design specification set out by the client. One of these

designs will either be manufactured from Titanium, Aluminium and Carbon Fibre.

Here this details on each concept design:

Concept 1 (See Appendix 2) – This concept is your normal 5 spoke alloy wheel in

which is used a lot as an alloy wheel for Ferrari as well as road cars. This was the

team’s initial selection for the final design because it is very commonly used for

Ferrari’s cars. However, it wasn’t the team’s final choice as it came second from the

weighted objectives method to concept two as the team thought it was very popular

and they wanted to go with a different design for the alloy wheel.

Concept 2 (See Appendix 3) – This concept is based around the client’s classic

Ferrari F40 back in the late 80s and early 90s. This type of design is designed in a

form of a star as a 5 spoke wheel and very common on classic sports car like the

F40. The difference between this design and the F40 alloy wheel is that this design

would be safe to use and will meet all the design specification. However, the

downfall is that it will take longer to manufacture due to its shape. But, it came first

from the objectives method and therefore is the final choice to into the final design

process.

Concept 3 (See Appendix 4) – This concept was determined by the team due to the

fact it was familiar to concept 1 in which it popular used. But, the difference between

the two is that this concept is a 5 split spoke alloy wheel and is generally used on

Ferrari’s such as the Ferrari F430. From the objectives method, it came in last as it is

a popular with sport cars and the team wanted to go with a different design.

Weight Concept 1 Concept 2 Concept 3

Cost 7 6 8 7

Aesthesis 8 8 7 8

Safety 7 8 7 8

Acceleration of

the Car

8 7 8 6

Withstand the

Torque

8 7 7 7

OVERALL TOTAL 274 281 273

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10. Modelling The team have decided as a group based from the weight objectives method that

concept two is the best and final choice to go into the final design process. The team

have contacted Ferrari to let them know that the final design will be done on

Autodesk Inventor to allow them to see the product as a 3D model.

11. Details of Final Design The alloy wheel will go into the final design process based on the second concept design and the client have approved that the alloy wheel will be made from Carbon Fibre due to the fact it fits within our budget and it’s properties compared to the other materials. The final drawing must require dimensions such as rim size, width size, pitch circle diameter and much more. The tolerance must be added to the drawing when shaping the rim, flange and more. In addition to tolerance, diameter and length of the nuts and bolts must be considered as they play an important role for the alloy wheel to perform correctly. To conclude, the final design will met all the conditions set out from Ferrari. They have also settled that the final design for the alloy wheel will produce on

AutoDesk Inventor (See Appendix 5). The benefits of which includes:

Creating a 3D model based on the concept designs and gives a 360° look to

how the alloy wheel will look like.

It can be used to create a prototype for when it is tested out and from this

project; it will be tested at the Silverstone track.

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12. Benefits of a Team Approach The team was managed by a Project Manager in which guided the team during the

design process and were communicating on a regular basis to see what tasks

needed to be completed for each week. The tasks that needed to be completed were

split up within the team. Two members were doing the design process in which they

produced the concept designs and a fully detailed drawing on Autodesk Inventor.

The other members did the overall research of the project as well as the simulation

and modelling. Overall, the tasks were done through a method called Concurrent

Engineering where numerous tasks were completed concurrently by doing it at the

same time. In addition, the team were communicating frequently during the project to

ask for help from each other and much more.

13. Evaluation of the Design Process The design process helped the team to consider the different styles and designs that

are currently on the market. The team learnt to consider the dimensional

requirements such as rim size, the material commonly used, the manufacturing

processes and the different styles. The design process in general allowed the team

to come up with different designs as three concepts. One of which worked and met

the criteria set out in the project specification and produced a final detailed drawing

on Autodesk Inventor.

I learnt that there are different styles of alloy wheels and I personally think that the

design process went well for our team.

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14. Appendix

Appendix 1 – Gantt Chart (Documentation Provided)

Appendix 2 – Concept Design 1 (Documentation Provided)

Appendix 3 – Concept Design 2 (Documentation Provided)

Appendix 4 – Concept Design 3 (Documentation Provided)

Appendix 5 – Fully Detailed Design as a 3D model (Documentation Provided)