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  1. Computer Numeric Control (CNC) Manufacturing of CO2 Cars - An Overview Stage 1 - Prepare Final Design for Manufacture in CAD / Fusion 360 (Done by the students) Check design for rules compliance REMEMBER - Your part to be machined must fit within the dimensions of the standard Foam F1 Model block. The dimensions can be found in the Technical Regulations document. Add a machining reference plate to the 3D design. See details by clicking > Here Save your design as a .STL file in Autodesk Inventor and email to F1 in Schools Stage 2 - Submit a Manufacturing Request to YMC Find the online link (CLICK HERE). Fill the form and upload your car body (with reference plate attached) STL file. Manufacturing Costs: Standard machining = AED 368 (inc VAT) per car (this includes all resources and full standard car wheel and axle kit) Additional machining operations = approx AED 50 each per operation. (Some designs will require additional machining to create detail on the top or bottom of the car that isn't accessible through standard side machining. Don't worry, the team at Yas in Schools will check for this and inform you if it is required) Stage 3 - Computer Aided Manufacture using QuickCAM Pro (Done by the manufacturing centre) The 3D car model is converted to machining code. This is known as G-Code and includes all of the X,Y and Z co-ordinates that describe the profile of the car along with cutting speed, feeds and other instructions for the machine cutting operation to follow. Click the thumbnail below for an example of what this code looks like. Stage 4 - CNC Machining (Done by the manufacturing centre) Cars are machined on a DENFORD 3D CNC Router see this link for more information about these machines - http://www.denfordat...ompact-1000.pdf The Foam F1 Model blank is mounted in a special F1 in Schools Machining fixture Standard Machining, with the car oriented on its side commences via material being removed leaving behind the profile of the car design Here is a video of a typical CO2 car machining operation.... Stage 5 - We deliver the completed car body/s and wheel kits to your school! We will be developing more detailed classroom friendly resources that help explain the Design through to Manufacture soon. If you have any suggestions or comments, please reply to this post...
  2. Skills One visits Menai High to see the six step process involved in the F1 (Formula One) school program. See more SkillsOne TV videos at www.skillsone.com.au
  3. At Yas Marina Circuit we can manufacture your F1 in Schools car body for you! Simply click on the link below to make your request and upload your file. CLICK HERE TO SUBMIT A MANUFACTURING REQUEST Please ensure you have first read all the other guidelines in this forum for preparing your car design for manufacture
  4. Finished your car design - What next? Before making a request to have your design manufactured by Yas Marina Circuit there are some important things to do and consider: Check that the design complies with the Technical Regulations - most commonly students will design cars which are too long, too wide or too tall. It is important to check the maximum permitted car length in the regulations. Car bodies are not permitted to be as long as the actual Foam Model Block. This is because a portion of the Foam Block is held via a clamp during the actual CNC machining process. Ensure that no part of the body or other features such as wings which are to be made from foam block protrude beyond the block width of 65mm and block height of 50mm Wings designed to be manufactured from the foam block which are less than 3mm in thickness could break off during manufacturing and will be more prone to breakage during racing. The final step in Autodesk Inventor, in preparation for manufacture, is to add a manufacturing reference plate to the rear of the car. Instructions for this are presented below. The car body with reference plate added must be saved in .STL (stereo lithography) file extension format. This file format is required for compatibility for use with the CAM (Computer Aided Manufacture) software used by us to generate the machining code. ADDING A MACHINING REFERENCE PLATE Add the manufacturing reference plate | save as .STL | upload the .STL when submitting your manufacturing request to YMC F1 in Schools The final step before uploading your manufacturing request and completed design is to add a manufacturing reference plate as per the instructions document linked below. The reference plate is used during the CAM process to accurately locate your car model relative to the pre-machined C02 cartridge hole in the actual foam F1 Model block. Adding Manufacturing Reference Plate: AD Inventor-Add-reference plate guide.pdf EXPORTING THE CAR BODY INCLUDING REFERENCE PLATE AS A .STL FILE The following linked PDF explains how to export your design as an STL correctly. It is important to check this document as it explains how to export the file in the correct dimensional format. Autodesk STL Saving.pdf (Thanks to Jonathan Roberts from Repton School for sharing both of the above support files) If you have any questions or suggestions, please post them here by replying to this topic...
  5. This one page guide is very useful for helping machine operators remember the basic steps involved in set up and procedure when using a DENFORD 3D Router for manufacturing CO2 cars (F1 or Bloodhound). Post a reply here if you have any suggestions. DENFORD ROUTER - CO2 Quick Start.pdf
  6. QUESTION FROM A SCHOOL... We've got a problem, the motor will not run for the spindle. It stopped during a job after cutting for 40mins through bolsa wood using a 6mm ball nose cutter. It ran fine then stopped, starting twice for a sec before stopping completely. All other motors and switches are still working. The relay kicks in and there is an 230V ac output from the board. But the spindle motor is unresponsive. Thoughts? YMC F1 IN SCHOOLS REPLY.... Here are some things to try, but I'm guessing you may have ticked them off already... Check on / off switch on Kress motor has not tripped to the off position. Take the Kress motor out of the MRC 40 and plug directly in to 240v mains supply, will the motor power up. Let me know the outcome please. What next..... Carbon brushes need replacing or motor faulty. (Hope not!) Roughly, how many hours do you think the motor has run? We have emailed Kress in Germany to see if they have an agent in Dubai if the carbon brushes need replacing. Also - I've taken the liberty of adding you to our contact DB and you will be receiving future F1 in Schools related announcements. Ok? Another comment - 45 min cycle time for one side of a car is very long, usually 12-20 mins is normal... I've had the motor out and checked the switch, which is locked in the on position. Then tried a mains straight to it and nothing. I would say it's only had 35hr run time of which the maximum single cycle has been 45min. I'm a little cautious of opening up the motor in case it voids the warranty. The spindle is free to move and there is no grating sound which makes me think it might just be a dry solder or lose wire. Thoughts? I wasn't cutting a car at the time. It was after an area clearance with 5 mm step down and the feedrate nothing more than it should be able to cut in balsa (it wasn't struggling). Thank you for your swift reply.
  7. A great way to get started with students or to promote the project within your school is to use the PowerPoint presentation available for download from the link below. F1inSchools-Overiew-V1.pptx The presentation includes several videos and these will be streamed directly into the presentation from YouTube, therefore it is necessary to be internet connected to view these. Each video takes a few seconds to load. You may also need to allow access to external sources (YouTube in this case), if prompted by your computer when opening the file.
  8. A 3 Axis CNC Router the Denford 2600 Pro shown here cutting an F1 in Schools car with the F1 in Schools Car Manufacturing Fixture.
  9. An overview of the how the F1 in Schools technologies are used by studnets through the different stages of the F1 in Schools program
  10. F1 in Schools - MAKE Used to convert your F1 in Schools car body CAD model into special code to enable manufacturing on a CNC router. QuickCAM Pro is an advanced, yet simple to use, wizard based CAM package, which is used to create cutter paths for machining 3D parts on a CNC milling machine or CNC Router. See pdf for more detail and contact us f1inschools@ymc.ae for purchasing enquiries. quickcam-pro.pdf
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