F1 Racer

The Monolithic F1 Project was carried out by James Pitts as an undergraduate researcher for the IMS-M Laboratory. The main objective of this project was to provide James an opportunity to gain hands-on experience with, Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), and associated manufacturing procedures. The workpiece to be manufactured was a small scale monolithic Formula One Racecar, possessing superior surface quality and therefore requiring no post-milling polishing. Due to the use of Sodick 3-Axis machining centers, in conjunction with the complexity of this workpiece, extensive attention was focused on the precision and accuracy of the custom designed fixturing system.

Through the utilization of an iterative process of design, evaluation, and testing, multiple versions of the Monolithic F1 were created. In order to further expand James' understanding of manufacturing, various materials and scales were created. Each consecutive version possessed enhanced overall surface quality, with respect to its material, while at the same time achieving reduced overall production times.

Once primary prototyping of a hardened steel 40mm Monolithic F1 was completed a mass production study was begun utilizing a Sodick HS150L Linear machining center equipped with an Automatic Workpiece Changer (AWC). The AWC enabled near continuous operation and therefore better approximate industry level manufacturing.    To date in excess of 300 pieces have been produced.

Upon graduation James participated in an Internship with Sauer GmbH, Germany. The focus of his work was Rotary Ultrasonic Machining (RUM) of hard / brittle materials. Throughout the course of his internship a BK7 glass version of the Monolithic F1 was created, as seen above. James's current graduate research focuses on RUM surface quality optimization of glasses and advanced ceramics.   

A detailed report of the Monolithic F1 Project can be found below.

Machine: Sodick HS150L

Work Material: T6061 Aluminum

Machining Data:

Process Top Operations Left Side Operations Right Side Operations Bottom Operations
Total Cycle Time 111 min 34 min  34 min 16 min
Tool Size/Type

D6 flat end mill

D2 flat end mill

D1 flat end mill

R0.5 ball end mill

D6 flat end mill

D2 flat end mill

D1 flat end mill

D0.3 flat end mill

R0.5 ball end mill

R0.25 ball end mill

 

D6 flat end mill

D2 flat end mill

D1 flat end mill

D0.3 flat end mill

R0.5 ball end mill

R0.25 ball end mill

 

D6 flat end mill

D2 flat end mill

D1 flat end mill

R0.5 ball end mill