USM SEM Car Mold Fabrication

The mold for the SEM car is still in progress and the is expected to be completed on 1st week of January. The car will be completed by end of January 2010 and not end of December 2009 as planned.

Preparing the Fiberglass Mold

Before the shell can be fabricated, the mold has to be produced. Based on Solidworks drawings, the cross-sections of shell were printed in 1:1 ratio on A0 size paper. The 2D profiles were transferred to plywood and cut according to its shape. Each ribs were then attached to the base profile using brackets.
After printing using plotter the paper was cut according to its profile

The 2D shape of profile are pasted to plywood

Ribs profile are cut according to its shape using jigsaw

The ribs were placed at equal distance from each other

Ribs being installed to top mold

Bottom Mold

The ribs will be soon filled with PU foam and before fiberglass hand lay up can be done.

Hock Shen preparing the PU chemical mixture


Ribs ready to be filled with PU foam

Filling the PU Foam

Vanilla Ice cream?
Pu foam are left to solidify

Trimming the excess Pu foam

Upon filling with PU Foam the mold was later trimmed and one layer of glass fiber was added to give the mold surface better strength.

Top Mold
Bottom Mold

Chopped strands Glass fiber layers were then applied onto the mold to produce the shell.

PepRally By Prof.Horizon

As going gets tough, the tough gets going. Prof.Horizon had a special motivation session with all the SEM Team members for fabricating the SEM cars. After his motivational and team strategies, everyone were fully energized and motivated.

Competing the mileage of the European and American is a big challenge, he added.

He had also reminded that SEM is a International event. Hence, we have to fabricate a robust car design that is on par with other cars.

USM SEM Car CAD Models

Finally the USM SEM car has been decided. The SEM car is an enclosed wheel with tear drop shape.

Top view of the car

The chassis of the car is made of mild steel and shell made of fiberglass. The window are made of Perspex. Currently, the car is still in design refinement.

USM SEM Team Members in Action

Grinding!!!

Drilling!!!

Cutting!!!

Welding!!!

Laughing!!!

November Progress

Semester break has started and SEM team member have begun the fabrication of USM SEM car. Based on current progress, the car will be completed at the end of December 2009.
The team comprised of Running Gears, Engine, Body, Modeling and Propaganda team has started fabrication of parts required for the car.
A wire frame of the car was made to visualize the car's shape
One of the challenge for the body team was in ergonomics of the car. Since the car's maximum height was limited to 1m, the driver had to lie down. In addition of that, there must be 5cm clearance from top of the car to the driver's helmet. As a result ergonomics investigation had to be done using mock up ergonomics test rig.

Ergonomic test rig to test driver's sitting position
Various driving position were tested
The ergonomic test rig is now being redesigned

Technician Mr.Sani were also present give us help

Final position of the driver has been determined and the new chassis is being weld

With much confusion, finally we had managed to get a 16 inch front wheel. The next challenge is to attach a disc brake and subsequently attach to steering system.

Rear wheel placement discussion. Due to compactness of the car, the chassis has to be made simple.

SEM General Meeting

There will be a meeting to plan the holiday tasks and manpower resourcing.

Venue: MEK 2

Time: 2 pm

Date: 10th Nov

All Students who participated in SEM, please attend this meeting or you can check the outcome in enignes lab/ SAE lab if you unable to attend.

Thanks.

-Dave