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Sprint car wing

Question asked by Jose Sánchez on Jun 23, 2016
Latest reply on Jul 10, 2016 by Dennis Bacon

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Hello everyone

I modeled up this sprint car wing.

I want drawings to be able to make more wings but I ran into an issue

Hopefully somebody can help me out

So in img1 you can see the wing with sheets covering it

Img 2 is the wing without the sheets

and img 3 is the side view of the wing

The idea was to draw everything up so I wouldn't have to hand drill all the holes on the sheet

but in order to get it to fold over the wing, I had to make a bunch of bends as shown in img 4 the blue line

In order to be able to cut the part

I have to save a DXF of the flat pattern

the issue is, when I have the part cut and put it on the wing, the holes are not matching up

I don't know if its the bends throwing everything off or what's the problem

So basically what i'm asking

is there a way to create a sheet metal sheet over the wing, which is not flat, and be able to make holes in it that will hopefully match the wing

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img4.JPG56.5 KB
img 3.JPG41.8 KB
img 2.JPG90.5 KB
img 1.JPG103.5 KB

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David Robertson Jul 4, 2016 12:15 PM
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Hi Jose

I think the only thing you would be able to do is to sketch out the outline on one side (img 3 orientation) and create the base flange that way, adding the correct bend radii and parameters you need. Then add the holes using Extruded cuts or the hole wizard using the existing holes as references. Then you'll be able to flatten the body and still have the holes in it.

Kind Regards
David Robertson
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- Jose Sánchez @ David Robertson on Jul 4, 2016 3:18 PM
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  David
  
  This is how I made the sheets covering the wing
  I did not however change any of the bend radii
  I think as of now it is at the default radii that solidworks uses
  I will put it at the minimum possible and see if that helps
  thanks!
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Paul Salvador Jul 4, 2016 2:17 PM
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... tolerances from the process(es) alone would require your holes to be oversized,... which brings in a practical question.. 3-5 assemblys? (not mass production) ,.. if it were less then 5 assemblys,.. maybe consider clamping/drilliing/riveting at the point of assembly?
..and, maybe consider making the sheets larger curved panels, not the smaller facets and drill/rivet at the final assembly?

oh, the holes would only be on the exterior panels, for piloting (drilling/riveting), not on the small flanges under.

(btw, fun project!)
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- Jose Sánchez @ Paul Salvador on Jul 4, 2016 3:42 PM
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  Paul,
  If I could oversize the holes I would however, If I oversize the holes, the rivets will not hold the sheet onto the frame
  unfortunately they have to be the same size
  as far as the number of assemblies, the purpose of making drawings for it is to eliminate the clamping/drilling/riveting at the point of assembly. As of now, that is how these wings are made
  when the sprint cars crash or flip, you basically need a new wing because they are made of very thin materials
  so the overall idea is to be able to send DXF files to a shop and have them cut these parts with a laser, then bend them and all that would be left would be to assemble them.
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Dennis Bacon Jul 4, 2016 7:52 PM
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Hose,,, (Ooops) Jose,,, I have done many sprint car wings in my time. It actually can be done. I have made kits and shipped thousands uh,, hundreds of kits to people to put together on their site. Never had any complaints about the holes not lining up. I definitely would not bend the wrap in multiple hits like your pic. I goofed on my example and used a spline in order to quickly come up with a profile for this. Should have used tangent arcs then extruded a base flange but I'm getting old and tend to forget things so I ended up doing a loft. Also the wrap should be made in 2 or three pieces and overlap, but you get the idea. There are some good example of kits you can buy on various web sites.
I attached a 2014 file (earliest version I have). You can click on each body and flatten the ribs or wrap.
As Paul mentioned you do need some clearance holes in the wrap. We used to hammer the rib flanges over a lasered out piece of steel (or wood) but ended up making a tool to wipe the flanges.
This is a scaled down version an no attention was paid to hole placement or diameter (they are in line), flange length or over all.
Second Edit:... Just wanted to make it clear that the hole ° in the spars is the manufacturers recommendation for the rivet. I believe (can't remember for sure) that the holes in the skins were somewhere around .016" larger on a 1/8" and 3/16". Made my own shaker shook apart a lot of wings prior to coming up with the optimum clearance hole diameter which would maintain structural integrity and still be able to line up the holes.
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- Wing A Ding.zip2.8 MB
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- Jose Sánchez @ Dennis Bacon on Jul 9, 2016 9:45 PM
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  Dennis
  I have tried to do a wrap
  but I can't seem to get it to work
  can you explain in a little more detail how to go about doing the wrap?
  
  I actually have a custom made wing that a friend made, and the sheets do overlap with each other
  and the rivet holes are in fact 1/8 inch
  
  The whole idea of this project is to make it a lot easier to make more of these wings as when the sprint cars crash or flip, the wings are pretty much useless
  as of now the wings are made by hand
  which takes a lot of time
  and since this wing is custom made, it cannot be purchased
  
  I do thank you for your help, now I know that it definitely is possible to get this to work
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- Jose Sánchez @ Dennis Bacon on Jul 9, 2016 11:01 PM
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  If i'm not mistaken, I cannot do a wrap on an assembly?
  I guess that is what I am having a problem with
  In the pictures I attached in my question,
  it's the assembly of parts
  so is there any other option other than a wrap?
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  - Dennis Bacon @ Jose Sánchez on Jul 10, 2016 7:56 AM
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    I apologize for the confusion Jose. I am calling the skin that wraps around the spar a wrap. I did not want to suggest you use the wrap feature. A Base flange works for each of the 3 skins. I have a feeling that is what you used in your pic but there seems to be way too many bend lines (or tangent lines). You can do this in a part or an assembly. In an assembly you can start a new part and convert the edges you want as base flanges then extrude. I have done this in a part only creating a multi-body sheet metal part.
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Sprint car wing

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