WF01 | THE CARBON FIBER SPORTS CAR

WRITTEN BY: ROBERTO PAPALIA

10 OCTOBER 2018

Roberto Papalia

The requirement of a Sports car completely made of Carbon fiber and compatible with the strict FIA-CN2 competition gave birth to this demanding and challenging project back in 2009..

A Sport Prototype car with a monocoque chassis built in composites, “soaked with air”, with rigidity characteristics, weight and aerodynamic efficiency unseen so far in this category. The chassis philosophy is more similar to LMP car than Sport Prototype Car class.

.Challenged both by the project’s complexity and the stringent deadline, Nova was requested to engage all its prior experience gained in aerospace and automotive sphere, to deliver this highly distinctive engineering project. The delivery deadline for this project was set to the end of July 2009 in order to enable subsequent manufacturing and homologation phases, and eventual racetrack testing by the end of November 2009.

The WF01 Project,  (the official name was unveiled at the car’s presentation) remains an example of how effective management capabilities combined with technical expertise and diversified experience have contributed to a winning solution driven by passion and creative impulse

  In its category the WF01 represents a true and distinctive break from the past, as to the applied technical contents and approach  

  Best in class  

The choice of the design and simulation equipment to support the technical-scientific preparation of the engineers.

  First time right  

Creating the object accurately with attention to the details starting from the first version

  Parallel engineering  

enabling  an efficient flow of information by cutting drastically the time needed for the information to pass from one technical area to the others

In order to maximize accessibility throughout the diverse phases of intervention, reparation or set-up, a various bodywork parts are divided into subassemblies (fig A).

The removable front cover (fig B) allows the access to all front suspension components, and  illustrates the mounting / dismounting possibility using only four fixings.

The last task was to find a way for to reduce the front part vertical obstructions in order to improve visibility.

the Interface zone between the rear roll-bar and the chassis is particularly high in order to allow enough space to make, directly into the chassis, fuel filler openings, two one each side studied for endurance races. Chassis shape continues on roll-bar fairing without discontinuity, cleaning airflow directed to rear wing.

The last task was to find a way for to reduce the front part vertical obstructions in order to improve visibility.

Details

A heart of the car, this component fundamentally originates as a really innovative element for the vehicles of this category. The objectives were torsion and bending rigidity, with requests in terms of security that are related, on the other side, with definitely low targeted weight.

 

To achieve this goal, as the composite materials analysts have made choices without compromise, the only way to follow was that to intervene on the chassis’ shape, from one side to the other, pushing to the extreme the lay-up optimization of carbon layers, their shapes and orientations according to the most extreme conditions of employment. The experience gained in aerospace and tight collaboration with suppliers of the highest level have granted achievement of the winning posts.

Aerodynamics

In this case also, the requests in terms of “down force”, load distribution and aerodynamic penetration have put the designers in front of the great challenge.

 

Once more, the numeric simulation, as is already a custom in the highest level categories, has been of fundamental importance for subsequent testing, during the driving of the car, the benefits of certain solutions, or exclusions of others.

 

The most critical point of the project has been the research of the increased load on the front axle, obtained by the tall nose design and the specific study of the flow around the front splitter.

Suspensions

Considering a rapid evolution of this category cars, aside from the traditional scheme of the rear suspension, from the very beginning of the project a front suspension architecture is devised in a way that could anticipate two different schemes: a double wishbone with push rod for centrally mounted single shock absorber or, alternatively, an innovative system with tree shock absorbers, as a subject of recent developments.

 

A suspension mechanisms and its dynamics are studied during so called multi body simulation, introducing a bending of the components, apart from the detailed definition of flexible and damping elements.

Car homologations

A final step of the GB08 project was the FIA homologation, comprising all static and dynamic tests, predicted by regulations, and conceived, in fact, to guarantee security of the driver. As is already mentioned, for this purposes served the crash test, even if all the rest checks satisfied requested norms, but above all in order to give a full value to the simulations done on the computer, confirming that way a methodological validity.

Tools

  • Pro-Engineer |  Modeling of parts and surfaces
  • Hypermesh-Hyperview | Numeric simulations pre-post processing
  • Nastran | Static case of composites structures
  • Radioss | Crash calculation
  • CFX | Computational Fluid Dynamics simulation

* The choice of the tools used in this project was determined by the client. NOVA uses various software for both simulation and modeling

With great united passion for motor sports NOVA has delivered  successfully, together with its partners  a  complex project which contained extreme technical challenges concerning  the fundamental features of this Sports Car.

About Nova

Nova is a leading engineering company providing advanced technological solutions, product design and development in a broad range of mechanical engineering disciplines as well as comprehensive engineering consulting services to leading companies worldwide.

.Challenged both by the project’s complexity and the stringent deadline, Nova was requested to engage all its prior experience gained in aerospace and automotive sphere, to deliver this highly distinctive engineering project. The delivery deadline for this project was set to the end of July 2009 in order to enable subsequent manufacturing and homologation phases, and eventual racetrack testing by the end of November 2009.

Roberto Papalia

WF01 | THE CARBON FIBER SPORTS CAR

WRITTEN BY:  ROBERTO PAPALIA

01 OCTOBER 2018

The requirement of a Sports car completely made of Carbon fiber and compatible with the strict FIA-CN2 competition gave birth to this demanding and challenging project back in 2009..

A Sport Prototype car with a monocoque chassis built in composites, “soaked with air”, with rigidity characteristics, weight and aerodynamic efficiency unseen so far in this category. The chassis philosophy is more similar to LMP car than Sport Prototype Car class.

Roberto Papalia

Challenged both by the project’s complexity and the stringent deadline, Nova was requested to engage all its prior experience gained in aerospace and automotive sphere, to deliver this highly distinctive engineering project. The delivery deadline for this project was set to the end of July 2009 in order to enable subsequent manufacturing and homologation phases, and eventual racetrack testing by the end of November 2009.

The WF01 Project,  (the official name was unveiled at the car’s presentation) remains an example of how effective management capabilities combined with technical expertise and diversified experience have contributed to a winning solution driven by passion and creative impulse

  In its category the WF01 represents a true and distinctive break from the past, as to the applied technical contents and approach  

  Best in class  

The choice of the design and simulation equipment to support the technical-scientific preparation of the engineers.

  First time right  

Creating the object accurately with attention to the details starting from the first version

  Parallel engineering  

enabling  an efficient flow of information by cutting drastically the time needed for the information to pass from one technical area to the others

In order to maximize accessibility throughout the diverse phases of intervention, reparation or set-up, a various bodywork parts are divided into subassemblies (fig A).

The removable front cover (fig B) allows the access to all front suspension components, and also illustrates the mounting / dismounting possibility using only four fixings.

 

The last task was to find a way to reduce the front part vertical obstructions in order to improve visibility.

Interface zone between rear roll-bar and chassis is particularly high in order to have enough space to make, directly into the chassis, fuel filler openings, two one each side studied for endurance races. Chassis shape continues on roll-bar fairing without discontinuity, cleaning airflow directed to rear wing.

 

The last task was to find a way for to reduce the front part vertical obstructions in order to improve visibility.

A heart of the car, this component fundamentally originates as a really innovative element for the vehicles of this category. The objectives were torsion and bending rigidity, with requests in terms of security that are related, on the other side, with definitely low targeted weight.

 

To achieve this goal, as the composite materials analysts have made choices without compromise, the only way to follow was that to intervene on the chassis’ shape, from one side to the other, pushing to the extreme the lay-up optimization of carbon layers, their shapes and orientations according to the most extreme conditions of employment. The experience gained in aerospace and tight collaboration with suppliers of the highest level have granted achievement of the winning posts.

Aerodynamics

In this case also, the requests in terms of “down force”, load distribution and aerodynamic penetration have put the designers in front of the great challenge.

 

Once more, the numeric simulation, as is already a custom in the highest level categories, has been of fundamental importance for subsequent testing, during the driving of the car, the benefits of certain solutions, or exclusions of others.

 

The most critical point of the project has been the research of the increased load on the front axle, obtained by the tall nose design and the specific study of the flow around the front splitter.

Suspensions

Considering a rapid evolution of this category cars, aside from the traditional scheme of the rear suspension, from the very beginning of the project a front suspension architecture is devised in a way that could anticipate two different schemes: a double wishbone with push rod for centrally mounted single shock absorber or, alternatively, an innovative system with tree shock absorbers, as a subject of recent developments.

 

A suspension mechanisms and its dynamics are studied during so called multi body simulation, introducing a bending of the components, apart from the detailed definition of flexible and damping elements

Car homologations

A final step of the GB08 project was the FIA homologation, comprising all static and dynamic tests, predicted by regulations, and conceived, in fact, to guarantee security of the driver. As is already mentioned, for this purposes served the crash test, even if all the rest checks satisfied requested norms, but above all in order to give a full value to the simulations done on the computer, confirming that way a methodological validity.

Roberto Papalia

WRITTEN BY:  ROBERTO PAPALIA