Autodesk

Formula Car Design Curriculum 2009

The lessons are intended for use in instructor led training, or by students who have already completed an introductory Autodesk Inventor course. The examples are outlines of workflows in Inventor, and do not detail every step needed to complete an exercise, so an intermediate level of knowledge of Inventor or the support of an Inventor expert is assumed.

Lesson Overview
Lesson 1 provides several basic modeling exercises in which you create parts commonly used in race car suspensions including a rod end bearing, bellcrank, and suspension mount clevis. Lesson 2 starts with an exercise in modeling a single piece magnesium racing wheel. That is followed by an exercise in modeling a chain sprocket, where the defining equations drive the model. Finally, a portion of a frame is modeled using the Sweep tool. Lesson 3 starts with an upper control arm exercise in which 3D points are used to define the primary sketch plane. That is followed by two exercises in modeling a spring, the first using manual techniques and the second using component generator. Lesson 4 provides an exercise in the use of the powerful Frame Generator tool. Starting with spatial sketch geometry, you use specialized tools to define the centerlines and cross sections of frame members, followed by their joints and intersections. Lesson 5 is an assembly modeling exercise in which you bring together parts to form a working model of a race car suspension. Lesson 6 is a drawing creation exercise in which you generate and annotate multiple views of the bellcrank created in lesson 1. Lesson 7 is an exercise in the use of Inventor Studio. You create a stage for showcasing the race car model. It is used to generate a high resolution image of the car, and a video animation of the suspension. Lesson 8 is an exercise in the use of the powerful Dynamic Simulation tool. It is used to determine the required spring properties for both static and dynamic suspension loads, and to generate a graph of spring displacement with time. Lesson 9 provides two exercises in the use of stress analysis. The first bases the analysis on estimated load values, while the second bases the analysis on the results of dynamic simulation.

AutodeskFormulaCarDesign

Summary

Lesson 1 Basic Part Design I

This lesson consists of creating three relatively simple parts that are commonly found in race car suspensions: Bellcranks Suspension mounts Rod ends Creating these parts provides a good exercise in the basics of part modeling in Autodesk Inventor. Objectives After completing this lesson, you will be able to: Describe the essential characteristics and purposes of bellcranks, suspension mounts, and rod ends. Set Snap Spacing. Use construction geometry. Apply the Mirror feature. Use the Shell and Hole tools. Use sketch constraints. Apply the Fillet feature.

AutodeskFormulaCarDesign

Summary

Lesson 2 Basic Part Design II

This lesson consists of creating three moderately challenging race car components: Wheel Sprocket Front roll hoop

Objectives
After completing this lesson, you will be able to: Revolve a sketch around an axis. Create an offset work plane. Base a new sketch on a work plane. Use the Project Cut Edges tool. Apply the Circular Pattern tool. Create and apply User Parameters. Use Extrude with the Intersect option.

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Lesson 3 Advanced Design I

This lesson consists of creating models of the following two parts: Control Arm Spring In the final exercise of this lesson, you create a second spring using the Design Accelerator.

Objectives
After completing this lesson, you will be able to: Create and use work features. Use the coil feature. Sweep a cross section along a path. Use the Compression Spring Component Generator.

AutodeskFormulaCarDesign

Summary

Lesson 4 Advanced Design II

This lesson consists of modeling two parts: Frame Suspension Mount

Objectives
After completing this lesson, you will be able to: Create unconsumed sketches and geometry to define a frame skeleton. Use the Frame Generator panel and use its Insert tool to define frame members. Use the Miter, Trim-Extend, and Notch tools to refine frame member intersections. Create a part within an assembly. Use the Isolate tool. Create an adaptive part.

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Lesson 5 Assembly
This lesson consists of creating: Rod end bearing assembly Front suspension assembly

Objectives
After completing this lesson, you will be able to: Apply constraints within Autodesk Inventor assemblies.

AutodeskFormulaCarDesign

Summary

Lesson 6 Creating Drawings

This lesson consists of creating a detail drawing of a bellcrank.

Objectives
After completing this lesson, you will be able to: Set the background sheet color. Apply centerlines. Apply dimensions. Create a section view. Create an auxiliary view. Define and use a sketched symbol. Create a projected isometric view. Populate the title block.

Exercise: Create a Detail Drawing of the Bellcrank

In this exercise, you do the following: Set up the drawing. Create the base and top views. Dimension the front view. Create the section view. Define a sketched symbol. Create auxiliary views. Complete the drawing.

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Lesson 7 Rendering with Inventor Studio

Objectives
After completing this lesson, you will be able to: Apply a decal to a surface. Create a camera. Apply a surface style. Render an image.

Exercise: Render an Image

In this exercise, you do the following: Create walls. Apply a decal. Model the floor. Assemble the stage. Create the studio. Apply a surface style. Render a high resolution image.

Exercise: Render an Animation

Inthisexercise,yousetupandrenderananimationshowingthesuspensiongoingthroughitsrange ofmotion.

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Lesson 8 Using Dynamic Simulation

In this lesson, you use the tools of the Dynamic Simulation environment to determine front spring properties for a race car suspension.

Objectives
After completing this exercise, you will be able to Access the Dynamic Simulation environment. Create a spring/damper joint and external force. Run a simulation. Use the Output Grapher.

Exercise: Dynamic Simulation

In this exercise, you do the following: Prepare an assembly for Dynamic Simulation. Access Dynamic Simulation. Create a spring/damper. Determine the spring constant. Determine spring free length. Apply an external force. Run a simulation. Edit the applied force. Run the Output Grapher. Change the damping.

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Lesson 9 Performing Stress Analysis

In this lesson, you use the Stress Analysis environment to examine stress loads on an isolated part and a part contained within an assembly based on dynamic simulation.

Objectives
After completing this lesson, you will be able to: Access the Stress Analysis environment. Apply constraints and loads to a part. Generate a Stress Analysis solution. Modify the analysis mesh resolution. Perform stress analysis based on dynamic simulation.

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