Just like the progress made on the chassis, the suspension is going according to schedule as well. In order to speed up the production even more, we make use of spark eroding techniques from Ter Hoek. With spark eroding we save time compared to last year, when all geometry brackets were made by CNC milling machines.
Spark eroding is a machining technology with which materials can be milled extremely accurately by electrical discharges (sparks) between an electrode and the work piece. The great advantage of spark eroding is the complex shapes that can be made by using this technique. Therefore, it is very suitable to make geometry brackets for the DUT10.
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The production of the DUT10 is currently going on for 2 months. After some lack of sleep of some team members due to the deadline of the Structural Equivalency Form (SEF), a document in which we have to prove that our monocoque has the same structural properties as a tubular space frame, it was time for a relaxing evening last Wednesday. During the infinite supply of spare-ribs, many DUT Racing stories were cited. When the last DUT Racer was fed up with spare-ribs, the team returned to the workplace to prepare the DUT09 for the test of the next day.
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Many of our team members took the car or train to Hengelo in the eastern part of the Netherlands the past weeks. A lot of different team members have gained the experience of producing glass fibre and wooden moulds for some carbon fibre parts of our car. In cooperation with Groothuis BV. we were able to produce the third cockpit mould and the side pod moulds. Next to that also the steering, plenum, diffuser and fuel tank moulds were produced at Groothuis.
Every year the team produces many parts out of carbon fibre. These fibres fit well into our lightweight concept, but also allow for stiffer and more efficient designs. Using vacuum injection, we are able to produce all these parts in-house. The only parts we cannot produce ourselves completely are the moulds, which need to be air-tight. We are therefore very grateful to Groothuis for sharing their resources and expertise to enable the production of all these moulds.
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Last couple of weeks, the chassis team has been working hard on the production of the monocoque. First step was to finish all moulds and treat them with release agents. After this, the actual production could start. The monocoque consists out of 3 parts, the upperside was first in line. All layers of carbon fibers were positioned in the mould quite rapidly. There were no big issues during the placement of the fibers. Thanks to Fatol, who supplied the resin from Axson, it was possible to finish the production of the upperside at the beginning of last week. This was done by vacuum injecting the fibers with the resin. Everything seemed to go well, but untill the resin has not been cured completely, no clue can be made. Two days later the exciting moment occured: removal of the product from the moulds. Fortunately, the result was as intended!
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DUT-E Racing Delft has put a lot of effort into setting up a new Formula Student Electric team. Due to a combination of factors like the limited time until the first event and limited resources, DUT-E Racing Delft team decided not to take unnecessarily high risks and withdraw from the Formula Student Electric competition this year. The fact that DUT-E Racing Delft withdraws from the competition coming August, does not mean that DUT Racing permanently turns its back to Formula Student Electric.
We wish the other Formula Student Electric teams good luck and we would like to thank all parties involved in DUT-E Racing Delft for their support, effort and faith.
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Besides the production of the DUT10 during this time of the year, on average two tours per week are given to high school students.
By giving these tours, we help the TU Delft and hope that DUT Racing Team generates interest of the prospective students at the TU Delft in return.
The high school students get a tour by a motivated DUT team member through the hall where several other TU Delft student projects hold their office. In the workshop of DUT Racing they get to hear the history of the team and see the development of the cars over the past years.
Due to these tours, the high school students know which cool student projects are going on at the TU Delft and hopefully some of them will become future team members!
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The production phase of the DUT10 started and like last year, it starts with a luxurious relaxing weekend.
About 20 team members traveled down to the small town of Anloy in the snowy Ardennes. After a ride through centimeters of snow we arrived at our villa which had everything.. With 4 living rooms, 3 kitchens, 6 bathrooms and 2 games rooms with table football, table tennis, air hockey, pool table, darts, etc. it was a very good stay. Obviously, the beamer came along on which films were shown continuously.
After exploring the house for the first night, the idea was to find a ski piste in the neighborhood. But with the heavy snow it was almost impossible to drive and we decided to stay around the house. Nevertheless, there was plenty to do. After a good breakfast with Belgian baguette, Ardennes ham and eggs it was time for an active day which was filled by snowball fights, a little bit of football and then ‘levend stratego’ in the forest. after a good meal that evening, poker was played late into the night, films were shown and some people just relaxed in one of the baths in the house.
After a good night sleep and an extensive breakfast on Sunday the conditions were perfect for cross-country ski. One group went for 6 kilometer where others went even further and for 8 kilometer. But fortunately for all there was gluhwein and hot chocolate at the end to warm up again.
Back at the villa, the weekend ended with a big pile of pancakes, after which everyone traveled back to Delft.
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This month we already produced three impact attenuators, also called crash noses. Thursday the 21st of January we tested them at Corus. The crash noses need to absorb the energy of a car that weighs 300 kg and hits a wall with 25 km/h, quite an impact! Our crash noses are made of composite materials which makes them very light, about 800 grams for a nose. The tests went well, we now have a lot of valuable data to make our final nose, which we also have to test. This is to proof that that nose is safe enough to use at the competition.
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2 Minutes and 44.930 seconds. This was the time required to complete the 15 quiz questions of the Formula Student Germany registration. With a 9th place in this round of registration, the DUT Racing Team will be present at both events in Germany and England.
Every year, registration to events is a race as well. Unless you hold a top 10 position at a certain event from the year before, registration is not guaranteed. With our 2nd place at FSUK last year, participation to that event was certain. As we didn’t finish the endurance at FSG2009 and ended up 18th overall, we had to take the registration quiz.
As mentioned before, we will go to Formula Student in Germany with two (!) cars. The electric team DUT-E already registered to FSE last week. Both cars will start with number 85. In combination with the addition E for FSE, the DUT-E team will start with number E85, the fuel of the DUT10.
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Just like the progress made on the chassis, the suspension is going according to schedule as well. In order to speed up the production even more, we make use of spark eroding techniques from Ter Hoek. With spark eroding we save time compared to last year, when all geometry brackets were made by CNC milling machines.
