Serkan changes

.obsidian/graph.json

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vault/Serkan_Changes_Fall25.md

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+## Chassis Subteam Rule Compliance Checklist – Shell Eco-marathon 2026
+
+Chassis / Monocoque Construction
+
+- Monocoque or chassis must protect the driver, including crumple space in front, side, and rollover collisions.
+- A roll bar is normally required, but a panel-type bulkhead integrated into the monocoque can serve instead.
+- Roll bar or bulkhead must withstand a static load of 700 N without deforming.
+- Driver’s helmet must not protrude beyond impact area in a rollover.
+
+Bulkhead (Energy Compartment Separation)
+
+- Must be a rigid partition sealing propulsion and energy storage systems from the driver.
+- Must withstand open flame and prevent fuel, fire, or gases from reaching the driver.
+- Must prevent manual driver access to the energy compartment.
+- All holes must be sealed with fire-resistant material; wires and cables must pass through grommets.
+
+Vehicle Body
+
+- Must fully cover mechanical parts.
+- Commercial body parts are not allowed.
+- Two doors required (one each side), each providing at least a 500 mm x 800 mm opening, verified with template.
+- Doors must use hinges or sliding rails - tape, Velcro, or similar are prohibited.
+- Fixed roof required over the driver’s compartment.
+- Windscreen with effective wipers is mandatory.
+- Must include a luggage compartment of 500 x 400 x 200 mm with rigid walls, accessible from the outside.
+- No dangerous appendages; sharp edges must have a radius of at least 50 mm or be deformable.
+- A towing hook or ring is mandatory at the front, accessible, with at least 30 mm opening, and must resist the vehicle’s weight.
+
+Lighting (Urban Concept)
+
+- Vehicle must include:
+- Front headlight(s)
+- Front turn indicators
+- Rear turn indicators
+- Red rear brake lights
+- Red rear running lights
+- All lights must be symmetrical, clearly visible in both daylight and nighttime conditions.
+- Lights must be within 300 mm of outer vehicle edges.
+- Hazard light function is required.
+- Innovative or modern lighting designs are permitted if they meet functional requirements.
+
+Windows & Visibility
+
+- Driver must have 180° field of vision (90° to each side) without electronic aids.
+- Tint permitted only if driver remains visible from outside.
+- Two rear-view mirrors or equivalent video system required, each with minimum 2500 mm² area, weather-resistant, and functional in all lighting conditions.
+
+Access & Safety
+
+- Driver must be able to exit the vehicle in less than 10 seconds from both doors.
+- Doors must open with a single action, from both inside and outside, without tools.
+- Exit operation must be clearly marked with a standard sticker provided by organisers.
+- Driver seat must use a 5-point harness securely attached to the main structure.
+
+Dimension Rules (Urban Concept)
+
+- Height: 1000–1300 mm
+- Width: 1200–1300 mm
+- Length: 2200–3500 mm
+- Ground clearance: at least 100 mm (with driver and ballast).
+- Track width: at least 1000 mm (front), at least 800 mm (rear).
+- Wheelbase: at least 1200 mm.
+- Maximum vehicle weight (excluding driver): 225 kg.
+
+
+
+# Researching other successful Chassis
+
+<img width="1261" height="814" alt="Image" src="https://github.com/user-attachments/assets/aae4f0d9-ae16-4db3-a3e2-271884902abf" />
+
+
+## ITS Sapuangin won the Urban Concept Internal Combustion Engine (ICE) category at the Shell Eco-marathon three years in a row.
+
+### The one number that matters most is the drag area (Cd​A), which combines the car's shape (Cd​) and its size (A) into a single value.
+- The Sapuangin XI Evo 4.0 has a Cd​ of 0.14 and a frontal area of 0.88 m², which gives it an impressive drag area of 0.123 m².
+- Here are some of their notable features and strategies:
+- Underbody Aerodynamics (The Venturi Effect): This is one of their coolest innovations. The team's design is inspired by the Venturi effect to reduce rolling resistance. By intentionally having a low ground clearance, the car creates a low-pressure area under its body. This pressure difference generates a downforce of -7.24 N, which helps the car stick to the road and reduces the energy lost to rolling resistance.
+- The team relies heavily on data. They use Computational Fluid Dynamics (CFD) simulations to evaluate air resistance and visualize airflow before they even build the car. This helps them identify turbulent areas and refine their design. In a previous car, they used CFD to optimize the placement and height of vortex generators, which resulted in a drag reduction of over 5%.
+- Double-Layer Carbon Fiber Body: The Sapuangin XI Evo 4.0 uses a double-layer carbon fiber material for its body, which helps to reduce aerodynamic drag and contributes to a total vehicle weight of just 109 kg, with the body weighing only 14.8 kg. The body also serves as driver protection and helps improve fuel efficiency.
+- Innovative Use of Materials: The team even looked for creative ways to reduce weight in unexpected places. They introduced a composite steering wheel made from carbon fiber with a balsa core from repurposed wooden shipping boxes, which helped them win a Vehicle Design award.
+
+<img width="665" height="391" alt="Image" src="https://github.com/user-attachments/assets/96a74774-2c3e-4e27-b81e-924fb02b9b3f" />
+
+## Green Team Mecc competes in the Europe and Africa Shell Eco Marathon Urban Concept division, and had an efficiency of 142.9 Mi/kWh in 2024. 
+
+-  No formal data on drag coefficients or other key metrics posted, however their car has a very similar teardrop shape to our UC'25. 
+-  The team apparently uses a "Tank-to-Wheel" multiphysics model to analyse the vehicle's energy consumption. They take into account drag, rolling resistance, and gravitational forces to get a complete picture of all energy leakages. They also use CFD to test airflow on their aero.
+-  They are from Politecnico di Milano which has a renowned fluid dynamics lab
+-  Their design features enclosed wheel wells - advantageous for a few reasons
+
+- Wheels create turbulent wakes as they spin
+- Enclosing smooths airflow, reduces vortex shedding and helps maintain laminar flow along the body sides 
+- Even enclosing to the axle line might help massively, because this way the most turbulent region is shielded (top of wheel moves twice as fast as car)
+
+
+# Forged Carbon mold design research
+
+# 3D Printed Molds 
+
+## Process
+
+- A mold is designed in CAD and produced using a 3D printer (commonly PLA, ABS, or PETG).
+- The mold surface is post-processed (sanded, sealed, and coated with release agents or epoxy surfacing coat) to prevent resin leaks and improve finish.
+- Chopped carbon tow is combined with resin, pressed into the mold, and cured either at room temperature or in an oven.
+
+
+## Benefits
+
+- Low cost: Inexpensive compared to CNC machining or cast resin molds.
+- Fast turnaround: Ideal for prototyping and one-off parts, since molds can be printed quickly.
+- Complex geometry: 3D printing enables intricate designs and organic shapes without expensive tooling.
+
+## Drawbacks
+
+- Surface quality: Print layer lines and porosity require sealing and finishing
+- Thermal resistance: Thermoplastics can deform under heat and pressure during curing.
+- Durability: Limited lifespan; molds wear down quickly with repeated use.
+
+
+# Epoxy Resin Cast Molds
+
+## Process
+
+- A positive master model is created (via CNC machining or 3D printing).
+- The master is coated in a release agent, and epoxy tooling resin is poured over it to form a negative mold.
+- Once cured, the resin mold is sanded and polished, then used for layup of chopped carbon tow and resin.
+
+## Benefits
+
+- Improved durability: Stronger than 3D printed molds, capable of moderate thermal cycles.
+- Better surface finish: Epoxy resins produce smoother mold surfaces, leading to higher-quality part finishes.
+- Repeatability: Suitable for small batch production (multiple identical parts).
+
+## Drawbacks
+
+- Time-consuming: Requires creation of a master, casting, and curing before use.
+- Higher cost: Epoxy tooling materials are more expensive than basic 3D prints.
+- Limited lifespan: Still less durable than metal molds, especially under high pressure/temperature cycles
+
+
+# CNC-Machined Aluminum or Steel Molds
+
+## Process
+
+- The mold is designed in CAD and CNC-machined directly into aluminum or steel.
+- Precision machining allows for highly accurate surfaces and fine details.
+- The mold can be heated during curing and withstand compression molding pressures, ensuring a high-quality final product.
+
+## Benefits
+
+- High durability: Can withstand repeated thermal cycles and high pressures.
+- Excellent finish: Produces professional-grade surfaces with minimal post-processing.
+- Structural reliability: Best option for producing functional, load-bearing carbon fiber parts.
+- Long-term investment: Useful if the team plans to make multiple iterations or larger quantities.
+
+## Drawbacks
+
+- Cost: Significantly more expensive in terms of material and machining time.
+- Lead time: CNC programming and machining can take longer than 3D printing.
+- Overkill for one-off parts: If parts are not repeated, the investment may not be justified.
+
+

vault/Serkan_Layup.md

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+Wet Layup with Vacuum Bagging
+This process is done by hand, and involves manually applying resin to dry carbon fiber inside a mold. 
+
+Firstly, we must prepare the mold with a releasing agent. This prevents the finished part from sticking. Then, we cut sheets of dry carbon fiber to the appropriate size and shape for the mold. Next, apply a thin layer of resin to the mold. A layer of dry carbon fiber is placed on top and "wetted out" with more resin using a brush. We should repeat this method for every layer of carbon. 
+
+Next we must take precautions to ensure that the carbon fiber will set properly. These steps result in a part which is more consistent and has a better fiber-to-resin ratio. Vacuum bagging uses pressure to compact each layer together, remove air bubbles and squeeze out excess resin. Here are the steps: Firstly, apply one layer of peel ply to the wet surface of the carbon. Peel ply is a synthetic fabric, often with release agent, that allows resin to pass through it while also preventing the bag from sticking to the part. Next, (Optional), we can place a perforated release film on top of the peel ply. this film is used to control the flow of resin out of the part. Next, we should place a layer of breather/bleeder cloth. This cloth has two main functions: It allows air to be evenly distributed along the length and width of the part, ensuring consistent vacuum force. Secondly. it absorbs excess resin which comes out of the release film, thereby reducing the chance of the resin sticking to the stack. 
+
+(This step should be completed before even preparing the mold). Cut pieces of plastic to the required dimensions. The plastic should have more than enough surface area to form a complete bubble around the mold. Use tacky tape to join strips of plastic together, and ensure complete air tightness. Once the bag is ready to use, place it around the mold and seal it using more tacky tape. Cut a small hole in the vacuum bag and install the vacuum port connector. We need to place a small piece of cloth directly over the port on the inside to prevent the bag from sealing shut. Finally, allow the resin to cure under the pressure for the time specified by the manufacturer. 
+
+
+
+Prepreg Layup with Oven Cure
+This layup method may be useful for the manufacture of parts which will undergo high load. The prepreg process leads to a very high fibre/resin ratio, which is advantageous for several reasons. Firstly, since carbon is significantly lighter than resin, and the ratio of carbon is high, the part will be significantly lighter overall. Secondly, the mechanical properties of the part are improved. In a carbon fibre composite, the fibres provide nearly all the stiffness and strength. The resin mainly binds them together and transfers load between them. More fibres = the part can carry the same load at a lower weight.

vault/manufacturing-index.md

@@ -6,6 +6,7 @@
 - [Sanding](Sanding.md)
 - [Spraying](Spraying.md)
 - [Layup](Layup.md)
+- [Serkan_Layup](Serkan_Layup.md)
 
 ---