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Showing posts with label car. Show all posts
Showing posts with label car. Show all posts

Friday, 28 January 2011

How we use Catia V5 in the office

Once again, the automotive design offices are in a extremely privileged position to have the most advanced 3D CAD systems as standard. Whilst there are a number to choose from, throughout the majority of the 14 years I was lucky enough to be in various offices like McLaren Automotive, Caparo and Gordon Murray Design we all used Dassault Systemes CATIA.
Although the initial investment is often hard to justify, I 100% believe that if the software is used properly and used in as many of the design stages as possible (i.e. from initial concepts right through to even the hydrodynamics of a yacht) the costs can be justified.

Whilst it is easy for me to say that it can be used efficiently, after 14 years sitting behind my CAD screen, it is a daunting task taking on a new design tool such as this, and the hard bit starts right from the start when you try and decide which of the many options you want/need. In the marine markets these generally range from styling tools, naval architecture, general 3D CAD right through to the composite FEA software. And of course, if you have the budget, these options could end up costing a frightening amount of money. But in most offices, the users just need some surfacing and then some solid generating tools, together with the standard 2D packages. And in fact its not until you need to generate A-Class surfaces (exterior panels) for cars that you need all the top level surfacing tools, particularly if you are importing your hull and foil shapes from other software.



To cut a long story short, I believe that having a tool such as Catia will help everyone in a design office. And due to the fact that the design process withing Catia is all parametric, if you need to go back and change anything it is easy. This makes it significantly faster to create not only the first parts but also the next parts if they are similar. It allows all the designers and engineers to see what everyone else is doing in the office as you can generate large assemblies on your screen and hence reduces errors. It will help to manage to the design process from start to finish, with its data management software called SmarTeam. This allows the engineers to do the design work, send it to the line managers for sign off, and then allows the rest of the office (purchasing, manufacturing etc) to see and download the relevant information.



To get over the first hurdle of trying to choose what I needed, I worked very closely with a company called Intrinsys www.Intrinsys.co.uk, in the UK. They are one of the companies that sell CATIA, and are the people you should go to if you are connected to the marine business. The main reason I chose to buy from them is that having worked with them when I was at Caparo, where they supported us in setting up our own unique solutions to how we wanted the design office to work, I know that whilst they are "salesmen" for CATIA, whats more important is that they are first and foremost, users of the software, and in fact the majority of their engineers on site are working on internal projects designing advanced automotive components for internal and external projects. This is vital when wandering down a "new path" as they were able to give me honest answers and will always be there on the end of the phone if it doesn't all go quite how I was hoping it might...! And for those of you thinking that your office just cannot justify this sort of software, then give them a call and I am sure you will be surprised just how much it might cost.....

So now I am in a position to be able to offer some help or design work to any of the design offices out there who are looking into using this type of software, or who have already chosen it but need more parts designed and engineered.

If any further details are required or if you may have a possible application for this process, then please contact us at any time at Info@LightBlackDesign.com

Wednesday, 26 January 2011

Sprayed Carbon Fibre

As mentioned in previous posts, Light Black Design  have been working closely with Bentley Motors in the UK, to help them develop a possible process to produce components for future cars within the VW Group.



Key to the engineering of these parts are the use of PUR for the matrix and combining this with a process developed by Bentley Motors called DCFP (Directed Carbon Fibre Preforming).



Key to the potential success of this process is the ability to "spray" chopped carbon fibres (approx 100mm long) onto the mould or part surface whilst still keeping a high degree of alignment of the fibres. This effectively gives you a composite panels with approx 80% of the properties of a Uni-directional tape, but with a fraction of the labour and material costs.


Whilst this is still being developed by Bentley for their automotive products, they are very keen to look at other possible applications, such as marine. I have spoken to them about several possible uses, and I feel that this would be perfect for monolithic parts such as RIBS and tenders. Here, the use of carbon is usually restricted due to material and labour costs, but with this process both of these will be reduced (the labour could even be removed if robots are used). And when every 10% you save in vehicle weight (be it boats or cars) you can save 7% of the fuel. And when you consider the fact that fuel is costing around £1.80 per litre on the rivers now, the potential saving in running costs cannot be ignored.

If any further details are required or if you may have a possible application for this process, then please contact us at any time at Info@LightBlackDesign.com

Tuesday, 25 January 2011

The "Taxi of Tomorrow"....

Late in 2010 Dan was contacted by Hexagon Studio, in Turkey, to work with them to specify the manufacturing processes for the Exterior and Interior Panels on their proposal for the New York Cities "Taxi of Tomorrow".

Whilst working closely with Hexagons Engineers we assessed all the feasible materials and processes, and then spent some time shortening the list until we had just the most viable options.

Having written up some detailed specifications of all the panels and their targets, we then contacted some potential Tier 1 suppliers, from a long list of companies we have worked with on previous automotive projects.

As they all came back to us, with all the relevant Part and Tooling costs, we compiled all the information and past it onto Hexagon to help them compile their Best and Final offer for their proposal to NYC.

NYC will make their final decision soon.

Lightweight Chassis concept for Bentley Motors...

CONCEPT CHASSIS DESIGN FOR BENTLEY MOTORS

We were contacted by Bentley Motors, in the UK, to help define the geometry and material specifications for an area of a chassis for one of their concept cars being developed by them in conjunction with the other sports car companies in the Volkswagen group.

Light Black Design - Bentley Motors

The baseline materials in this investigation are a further development of my previous work within automotive groups to produce lightweight yet extremely cost effective composite panels, which are viable for current automotive production lines. This technology will be combined with DCFP (Directed Carbon Fibre Preforming) the revolutionary process being developed by Bentley.

Most importantly, this technology has the potential to transform the way certain composite boats are made and even drastically reduce the overall costs. It may indeed close the gap between the cost of glass and carbon fibre boats, which will allow the industry to take advantage of the dramatically reduced running costs of the lighter carbon fibre boats.