Introduction The Process of Shaping Imagination into Reality Contents

Designing the Peregrine 389 car involves the 1. Introduction

Introduction • Autodesk Fusion 360
following steps: • Steps to design the car
In this engineering portfolio, we will showcase the journey of our team in the F1 in 1.Research and analyze F1 in Schools regulations and • Our Experience
Schools competition. We will explore our design and engineering process, technical existing cars. 2. Research & Design
• Aerodynamics
drawings, manufacturing and prototyping methods, testing and analysis procedures, 2.Develop multiple design concepts and select the most • Ideas inspired by tech
and our achieved results. Our goal is to demonstrate our passion, dedication, and promising one. • Streamlined Chassis
• Concept Evaluation
engineering skills throughout this competition. 3.Create a detailed 3D model using CAD software and • Rear pod
simulate performance. 3. CFD Testing
4.Build a physical prototype and test it for functionality • Evaluation Process
AutoDesk Fusion 360 4. Manufacturing
and aerodynamics. • The Process
Fusion 360 is a powerful computer-aided design (CAD) software that 5.Refine the design based on test results through iterative • CNC Milling
offers a wide range of tools and features to aid in the creation of testing. • Colours
• Painting
accurate and precise drawings. When it comes to creating detailed car 6.Finalize the design and prepare a comprehensive • Finishing
model, Fusion 360 was beneficial in several ways. presentation. • 3D Printing Wheels
5. Orthographic
Firstly, Fusion 360 provides a comprehensive set of modeling tools Effective collaboration, documentation, and feedback are drawing and final Car
that allowed Taha Shaikh (Design Engineer) to create complex 3D essential throughout the process. • Car Design
geometries with precision. The software offers features such as • Orthographic Drawing

parametric modeling, which enables the creation of relationships Our Experience

and constraints between different parts of the model. This ensures
that any changes made to one part automatically update the related Participating in this competition provided us with valuable learning experiences,
components, maintaining accuracy throughout the design process. including strong teamwork and collaboration skills, practical application of
Furthermore, Fusion 360 supports collaboration engineering principles, problem-solving abilities, and resilience.
and teamwork through its cloud-based platform.
Thereby all our team members could work on the We learned effective communication, division of tasks, and leveraging strengths. We
same project simultaneously, accessing the latest gained knowledge in aerodynamics, materials science, mechanical design, and
version of the design files and making real-time manufacturing.
modifications. This collaborative approach
ensures that everyone involved in the project has We developed problem-solving skills and adaptability. Overall, the F1 in Schools
access to the most up-to-date and accurate competition offered a holistic learning experience, preparing us for future
drawings, minimizing errors and inconsistencies. challenges and contributing to personal and academic growth.
 Ideas inspired by technology
Research and Design
The basis for getting the most out of the design concept was the extensive research
that allowed the development of the concept. The design team held meetings to
Aerodynamics come up with different concepts for cars and individual components. Our main focus
when developing the ideas was to ensure that each design improved the car's
Aerodynamics plays a vital role in car design, and the mathematical principles involved
aerodynamics. Below is an overview of the key design concepts developed from our
in optimizing streamlined wing shapes further underscore their benefits. The drag
research.
force (Fd) acting on an object is influenced by factors such as shape, speed (V), fluid
density (ρ), and reference area (A). Streamlined wing designs minimize the drag Streamlined Chassis
coefficient (Cd), resulting in reduced drag force and improved energy efficiency,
]enabling higher speeds. Caster resistance is one of the main factors that slows down a car. Air
Optimizing airflow involves considering fluid dynamics principles, such as boundary separated at the front of the car will try to move to a similar location at
layer theory and laminar flow. Computational Fluid Dynamics (CFD) simulations aid in the back of the car. However, if the object is not streamlined, the air
achieving smooth airflow, reducing turbulence and lift. This enhances stability and tends to create turbulence in the tail known as a wake vortex. The air is
control, crucial during high-speed maneuvers. basically trying to fill the vacuum in the back of the car, and that vacuum
slows the car down. The result is a chassis concept optimized over the
entire length of the vehicle.

Concept Evaluation
The process of developing the design concept essentially meant translating the
aerodynamic knowledge gained through research into a usable design concept.
What we wanted to improve was how we use research results to develop new
concepts. We have achieved this by finding research applications in real objects.
How Airplanes Generate Lift or How F1 Cars Use Coanda effect. The idea of ​applying
research to develop ideas is a skill engineers use every day. After adopting this
approach, we found the concept to be easier to develop.
Generating downforce (Fz) relies on wing shape, angle of attack, and size. The lift
coefficient (Cl) determines downforce production. By designing wings to increase Cl, Rear Pod
downforce and grip are enhanced, enabling better cornering.
The "Coanda effect" bends the air around the face by using the effects of
By utilizing these mathematical principles and conducting wind tunnel tests and unevenness and smooth surface processing. A car with a smooth surface can
simulations, designers refine streamlined wing shapes for maximum aerodynamic reduce the frictional resistance of the skin, but then create more turbulence.
advantage. The resulting optimizations improve speed, control, and overall Our design concept uses rough machining and textbook streamlined modeling
performance, giving the car a competitive edge. of the rear of the cabin to eliminate caster drag.
 This side view of our car clearly
CFD TESTING depicts the change in velocity as it
comes in contact with the car's
Evaluation Process surface. Evidently, the velocity is
smooth and effective over the main
The evaluation of an F1 in Schools car is crucial as it provides insights into its
body with the velocity decreasing by
aerodynamic performance, enabling design optimization for enhanced speed, stability,
only around 4% throughout the
and overall on-track competitiveness. To check the airflow for an F1 in Schools car using
curve. Next, We can also notice how
Autodesk CFD, you can follow these steps
the flow of air is smooth below the
1. Import the 3D model
car.
2. Set up the car's geometry and boundaries.
3. Define the fluid domain around the car. The airflow from the top view should
4. Assign materials to car components and air properties. a slightly concerning flow of air at
5. Generate a suitable mesh for accurate simulation. the sides of the car after its contact
6. Specify operating conditions and boundary conditions. with the wheel. The highly disturbed
7. Run the simulation until convergence is achieved. airflow at the sides, we realized, was
8. Analyze the results for airflow patterns, pressure distribution, etc. because of the design of the original
9. Make design adjustments based on the analysis. front wing which did not have
10. Iterate and refine the design for improved aerodynamic performance. enough surface area or curve to
direct the flow around the sides. This
prompted us to create a new front
This image clearly shows the overall design wing design which had a structure on
philosophy of our car in terms of airflow. either sides of the wing which was
The air flowing under the car from the enough to curve the air around the
nose to the rear of the car is completely car. OLD DESIGN NEW DESIGN
laminar. The air is compressed slightly to
increase velocity, then expands to the
same volume as it entered, joining with air CFD (Computational Fluid Dynamics) was instrumental in understanding our
from under and around the car flawlessly. car's capabilities. It allowed us to analyze airflow patterns, optimize the design
The main side pods handle the front wheel to reduce drag and enhance downforce, and predict stability and handling
casters well and direct dirty air around the characteristics. By virtually testing modifications, we saved time and resources
car instead of under it. All this contributes in the prototyping phase. CFD empowered us to make informed design
to an extremely aerodynamically efficient decisions, improve performance, and showcase the power of computational
BOUNDARY CONDITIONS vehicle. tools in engineering and design.
 Painting
Manufacturing
To achieve a sleek and shiny finish, multiple layers
The Process of high-quality automotive paint are applied. Each
layer is meticulously applied, sanded, and
The manufacturing process of the Peregrine 389 F1 in polished to ensure a smooth surface free from
Schools car involves various steps, including CNC imperfections. This process requires attention to
milling, using a polyurethane foam block, paintwork,
detail and precision to create a flawless
and incorporating the team's theme into the design.
appearance.
Additionally, it includes achieving a shiny finish,
irregular sanding for the Coanda effect, and 3D printing
the front and rear wings using SLS (Selective Laser Finishing
Sintering) technology. Moreover, the team incorporates the Coanda
effect into the design by performing irregular
CNC Milling sanding on specific areas of the car's surface.
To begin with, CNC milling is utilized by the team at Yas The Coanda effect is a phenomenon in fluid
in Schools to shape the Peregrine 389 F1 car. The dynamics that allows air to flow smoothly over
process involves the use of a Computer Numerical curved surfaces. By selectively sanding the car's
Control (CNC) machine to precisely carve out the body in irregular patterns, the team can
desired shape from a polyurethane foam block. The manipulate the airflow and optimize the car's
foam block acts as a lightweight and easily machinable aerodynamics.
material that allows for intricate designs and
aerodynamic considerations.
3D Printing Wheels
Colours For the front and rear wings, 3D printing using FDM (Fused
Deposition Modeling) technology is employed. It enables
After the CNC milling process, the next step involves the
paintwork of the car. The team carefully selects a paint rapid prototyping, cost-effective manufacturing, and
scheme that not only enhances the aesthetics but also customization of intricate components. FDM printing allows
relates to the theme of their team. The paintwork for lightweight structures , providing the team with the ability
serves both a functional and visual purpose, as it helps to optimize the aerodynamic performance of the wings. We
protect the car's surface from external elements while used ASA material and is considered to be stronger and
also showcasing the team's identity. lighter than the normal PLA material.
 Orthographic drawing &
final car
Car Design Orthographic Drawing

The rear wing follows a simple aerofoil

To ensure optimal structure with a 0 degree turn in order to
aerodynamics, we needed to maintain an equilibrium between down
redirect the airflow around the force and upforce
front wheels to eliminate
potential high-pressure areas.
However, excessive airflow can
create resistance against the
wheel's forward rotation due to
skin friction, reducing its axial
velocity. To address this, we
selectively deflect only the air
flowing above the front wing
over the wheel while allowing
the air flowing beneath the wing
to be redirected around the
wheel. This strategic approach
maintains the desired balance
between reducing pressure
buildup and minimizing any
The car’s body is designed to be
negative impact on the wheel's
completely curved and smooth, with
rotation. Orthographic drawings were essential in verifying our F1 in Schools
no interruption, air can flow smoothly
above and around all surfaces. car's compliance with technical regulations. They allowed us to cross-
check dimensions, proportions, and critical components, ensuring
The Peregrine Falcon, renowned for its remarkable flight abilities, can cover vast distances of up to adherence to specifications. Additionally, they helped assess safety
ten thousand miles in a single flight without expending excessive energy. Its wings possess a high features and overall design aesthetics.
aspect ratio and low thickness, allowing it to glide effortlessly over long distances without frequent
Rear Wing Front Wing
flapping. Drawing inspiration from this avian marvel, the front wings of the car emulate the low
thickness and chord of the Peregrine Falcon's wings, resembling its profile. Furthermore, the elegant Length (cm) 6.8 6.2
curve of the Peregrine Falcon's wings was incorporated into the design of the car's wings, not only Width (cm) 2.0 3.6
for aerodynamic efficiency but also for enhancing its visual appeal.
Height (cm) 1.0 2.5