Hasbullah Bin Mat Isa

8/19/2019 Hasbullah Bin Mat Isa

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DESIGN FABRICATION OF REAR CAR SPOILER

FOR PROTON WIRA MODEL

HASBULLAH BIN MAT ISA

A report submitted in partial fuifilmnt of the

requirements for the aw ard of

the

Diploma

of Mec hanical Engineering

Faculty of Mec hanical Engineering

Universi ti M alaysia PAHA NG

N O V E M B E R 2 0 07


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B S T R C T

Idea to fabricated of spoiler is appear after m ass production of accessory on

market this problem w ill make easily to get some information to fabricated or mak e

it and also to installation. For make the sketch it specification for a spoiler must be

have like an aerodynam ic flow o n the spoiler. Besides that beautiful and stylist also

will be taken for this fabricate.

By using fiberglass as a ma in material for this project because the fiberglass

has their own ad vantages that it has the higher of strength and it can hardly force

until 3 kilogram per time. The fiberglass also becom es the first selection m aterial

because it is light compare by using sheet metal. Wh en car is moving speedy on the

road the lift force unde r the car will increase. It will make instability to the car. With

fabricated this spoiler the driven level of car will be increase and com fortable when

this spoiler ma ke stabili ty again. It is becau se whe n the car mo ving speedy the

spoiler will produce the dow niorce to make n eutral from the lift force.

v


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BSTR K

Idea pembua tan spoiler mi terhasil setelah terdapatnya lambaka n penggunaan

aksesori mi dipasaran sekarang hal mi akan mem iidah dalam menda pat serba sedikat

tentang m akiumat mengenai cara pembuatan dan pemasang barang tersebut. Lakaran

yang dihasilkan adalah mempunyai spesifikasi pada sesebuah spoiler iaitu

membenarkan aliran aerodynamic path permukaan spoiler mi. Di samping itu juga

aspek kecan tikan dan trend terkini juga dititik beratkan.

Penggunaan gentian kaca pada bahan utama untuk pembuatan projek adalah

kerana gentian kaca mi mempunyai kelebibannya tersendiri yang mana ia

mempunyai daya ketahanan yang tinggi dan mampu menanpung hentakan sehingga

3 kilogam dalarn satu masa. Gentian kaca mi juga dijadikan pilihan atas sebab

sifatnya yang ringan. Apabila sesebuah kenderaan itu meluncur laju di atas jalan

raya daya apungan path kenderaan tersebut akan meningkat. Hal mi akan

menyebabkan berlakunya kurang kestabilan pada kencleraan tersebut dan

pemanduaan akan teijejas. Dengan rekaan spoiler mi tahap pemanduan path

sesebuah kenderaan akan thpat ditingkatkan apabila spoiler mi akan memberi

kestabilan kembali pada kenderaan dengan menghasilkan daya yang berlawanan iaitu

thya tekanan ke bawah

vii


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viii

T BLE OF CONTENTS

CH PTER

ITLE

G E

SUPERVISOR DECL R TION

DECL R TION

i i

DEDIC TION

v

CKNOWLEDGEMENTS

BSTR CT

i

STR K

ii

T BLE OF CONENTS

iii

LIST OF T BLE

LIST OF FIGUR ES

LIST OF PPENDICES

iv

INTRODUCTION

1 1 Background

1 2 Problem Statement

1 3 Im portant of project

1 4 Objective

1 5 S c o p e

1 6 Project outline


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i x

ITERATURE STUDY

2 1 Spoiler types

4

2 2 Bernoulli Principe

6

2 3 Aerodynamics

2 4 Material

9

2 4 1 F iberglass

9

2 4 2 Polyester

13

3

ETHODOLOGY

3 1 Research Methodology

5

3 2 Equipments

7

4

ESULTS AND DISCUSSION

4 1 Design and Development

3

4 1 1 Selection criteria

5

4 2 Step by step outcomes

9

4 3 Assem bly at vehicle

6

ONCLUSION AND RECOMM ENDATION

5 1

Conclusion and future prospect

8

5 2 Recommendation

9

REFERENCES

PPENDI ES

2


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L IS T O F T A B L E S

T A B L E N O I T L E

A G E

1 1

election criteria of eac h design

5


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L IS T O F F IG U R E S

F I G U R E N O

T I T L E

P A G E

1 1

Examp le of spoiler

2

2 1

Aerodynam ic of car

4

2 2

Air flow direction

2 3

Type of spoiler

6

2 4

Bernoulli Principe

6

5

Downforce principle

7

2 6

The effect of rear spoiler

8

2 7

Type o f airflow

8

2 8

Aerodynam ic affect

9

2 9

M olecular structure of glass

3 1

Project f low diagram

1 5

3 2

Equipments for making mould

1 8

3 3

Fiberglass

18

X i


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3 4

Hardener

1 9

3 5

Raisin or Polyester

1 9

3 6

Acid acetylene or acetone

2

3 7

Equipment of fabrication

2

3 8

W ax

2 1

3 9

Fabric glove

2 1

3 10

Cutting equipment

2 2

3 11

Measuring equipments

2 2

4 1

odel

2 3

4 2

Model II

2 4

4 3

Mo del III

2 4

4 4

odel N

2 5

4 5

Assembly drawing

2 6

4 6

Isometric view

2 7

4 7

Side view

2 8

4 8

Front view

2 8

4 9

Top view

29

x l i


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4.10

M aking mould

3

4.11

Measuring the material

3

4.12

Cutting the m aterial

3 1

4.13

Mixing hardener and raisin

3 2

4.14

Make first layer

3 2

4.15

M aking side of spoiler

3 3

4.16

Mating the blade and side part

3 4

4.17

Making stand

3 4

4.18

Spray the spoiler

3 5

4.19

Finished

3 5

4.20

Front view after assemble

3 6

4.21

Rear view after assemble

3 6

4.22

Assem ble car design

37

xl


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LIST OF PPENDICES

PPEN IX

ITLE

G E

antt chart

B

esign of part

C

imension of part

5

D

art of assembly

xiv


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C H A P T E R 1

I N T R O D U C T I O N

1 1 Background

By the use of modem technology, many equipments and devices are being

developed and brought to reality for human benefit and satisfaction. Am ong them are

the vehicles. These are m achines adorned with accessories that were engineered to

primarily bring artistic sense and appearance enhancement. A lso with the aid of

continuously technology ev olving, these accessories also work as very functional car

items [1].

Spoiler is just one of those impressive creations from h uman technology. It is

machined to bring sporty and cool look in a very trendy manner. However

ultimately, this auto accessory was designed to affect the ae rodynam ics of vehicle

from it s has been m ounted to. Particularly, cars that accelerate at top speed benefit

from its capacity [2].

A spo iler is an aerodynamic device attached to an automob ile whose intended

design function is to spoil unfavourable air movem ent across a body of a vehicle of

some k ind in motion.

his can result in improved v ehicle stability by decre asing lift

or decreasing drag that m ay cause u npredictable handling in a car at speed. Spoilers

are often fitted to race and high-pe rformance sports cars, although they have bec ome

Com mon on passenger vehicles, as well. Som e spoilers are added to cars primarily

for styling purpose s and have either little aerodynam ic benefit or even mak e the

aerodynamics worse [2].


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A car spoiler also improves the way that air flows over the vehicle Its

abutm ents and w ing like design features do this by disrupting the airflow so that the

vehicle can hand le better and mo ve faster. The result of affixing a spoiler to a car is

that car is has more traction on the road which can a llow it to go faster. Once the

installation of a car spoiler is accomplished car bec omes more stable and has less lift

or decreasing drag that might cause the car to handle in a dang erous or unpredictable

way if it is being driven at a high speed. Usually it looks like a b ig sleek tail a shown

in Figure 1.1 that uplifts the rump of the c ar or like a ledged wing [3].

V [ ThJ

Figure 1 1:

Exam ple of spoiler [4]

1 2 Problem statements

Althoug h spoilers are available in variety m ost of these are plain styling

comp onents that have little or no effect on the aerody namic prop erties of the veh icle.

There fore it is necessary to design spoiler that provided not only style but also for

aerodynam ic benefits.


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1 3 Im portance of the project

This project helps the student practice the knowledge and skill that has

gathered before in solving problem using academic research. This project also

important to train and increase the student s capability to get knowledge, research,

data gathering analysis making and then solve a problem scientifically.

1 4 O bjective

• To design a passenger car rear spoiler.

• To fabricate a passenger car rear spoiler.

1 5 Scope

• Passenger car rear spoiler for PROTON wira model

• Fabricated and assembly to real car.

• Material - Fiberglass and aluminium.

1 6 Project outline

This report will cover for five chapters, the first chapter is introduction,

second chapter is literature study and the third chapter is methodology. At chapter

four will cover for result and discussion, on the last chapter has covered the

conclusion and recommendation.


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C H A P T E R 2

L IT E R A T U R E S T U D Y

2 1 Spo iler types

Spoilers come in variety. The front spoiler or air dam can be foun d under the

front bum per in a car. The rear spoiler also know n as wing is positioned on top of

vehicle s trunidid to provide a downforc e when a ccelerating at top speed s for better

stabil ity shown in Figure 2.1. Another type is window spoiler. There are sam e other

spoilers which are exclusively crafted for pickups, including cab spoilers, tailgate

spoilers, truck cap spoiler and tonneau cover spoilers [5].

Figure11:

Aerodynamic of car [6]

The re are imp ortant things to consider in mo unting spoiler onto a vehicle.

ifferent spoilers possess different weights and adding them will affect the

performance in varying augm entations, depending on the m ater ia l that they were

mad e of. Most spoilers are made of the light and sturdy polyurethan e material. Other

is made from light weight steel or fiberglass [7].


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Spoilers are originally installed only on race ca rs and sports cars to redirect

airflow around their bodies. Specifically, spoilers were designed to disrupt airflow

going ove r a vehicle, decreasing the lift naturally gene rated by the shape o f the

vehicle and increasing the amo unt of force p ushing the vehicle s tires to the ground,

Figure 2.2 show n how airflow through onto a spoiler. As a result, racing vehicles can

turn, brake and ac celerate more aggressively. Today, spoilers are no longer limited to

racing vehicles and sports car [5].

ir low

Rear Wing

ngle of ttack

igure

2.2: Air flow direction [9]

Man y cars that fall into the sports-car or sporty-sedan classes com e with

factory-installed spoilers. Though a few spoilers are ac tually functional adding to the

aerodynam ic efficiency and stability of the vehicle at high speeds m ost are m erely

cosmetic and designed to add a sleek sporty look. Some enthusiasts like to

ex gger te th t look even further by repl cing the f ctory spoiler with more

aggressive looking after-marke t mo del. Installing one of these ad d-ons involves

removing the o ld spoiler and, if there is an integrated high-mount brake-light, doing

some electrical re-wiring [5].

Spoilers are available in quite a few styles. Some have top-mounted elem ents

that attach to the rear of the trunk or hatch (F igure2.3-A), and additional pieces that

attach to the top section of the rear fender. Others attach only to top surface of the

trunk or hatch. The e lements themselves com e unpainted (Figure2.3-B), so unless

you p lan to repaint your vehicle, i t will be necessary to have the p arts painted in

advance in a colour that is an exact m atch with your vehicle [5].


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Figure

2.3: Type of spoiler

[ ]

Figure A

Figure B

2 2

ernoulli Principles

A erodynamics is a branch of fluid mechanics that deals with the motion of air

and other gaseous fluids and with the forces acting on bodies in motion relative to

such fluids. The motion of an aircraft through the air the wind forces exerted on a

structure and the operation of a windmill are all examples of aerodynamic action.

Figure 2 4 shown how aerodynamic action related to Bernoulli principle that applied

to spoiler [10]

Figure 2 4:

B ernoulli principle [10]


17/24

Bern oulli 's principle is used in aerod ynam ics to explain the lift of an airplane

wing in flight A wing is so designed that air flows more rapidly over its upper

surface than i ts lower on e, leading to a decrease in pressure on the top surface as

com pared to the bot tom . The resul t ing pressure di fference provides the l i f t that

sustains the aircraft in flight. If the wing is turned u pside-do wn, the resultant force is

downwards. This explains how performance cars corner a t such high speeds. The

downforce in Figure 2.5 where the d ownforce produced pushes the t ires into the road

giving mo re grips [10].

i n g s

flgh presur above

w n

ow pressure below wing

igure

2.5: Downiforce principle [1]

An other impo rtant aspect of aerody nam ics is the drag, or resistance, acting on

solid bodies moving through air . The drag forces exerted by the air f lowing over an

airplane, for example, must be overcom e by the thrust force developed by the engine.

These drag forces can be significantly redu ced by stream lining the body. For bodies

that are not fully streamlined, the drag force increases approximately with the square

of the speed as they m ove rapidly through the air [12].

Spoi lers do a few things to reduce the drag pro fi le-a 3-D m easure of the

laminar (non-turbulent or flat air) and turbulent air pressure on the race car which

acts as a fr iction force against the c ar and increase pitch stability, while also aiding

the traction . Spoilers act in similar fashion to c reate lift and to stabilize air flows at

opposite ends of the vehicle example shown on Figure 2.6 [12].


18/24

Spoi ler

ear spo i ler creates a h igh press ure area

t h a t p u s h e d o w n o n r e a r o f c a r

Figure 2 6:

The effect of rear spoiler [1]

2 3 Aerodynam ics

Aero dynamics has p layed a ma jor ro le in car ra cing s ince the la te 1 960s,

whe n introduction of the f i rst inverted wings ap pea red in some formulas. After tha t

t ime, improved wing systems l ike the shap e of spoiler refer Figure 2.7) taken from

the a eronaut ic tech nology made leaps forwa rd, improving consis tently lap t imes,

increasing cornering speeds and vehicle stability. With the introduction of the gro und

effect a few years later the vehicles used a third element the under body) to produce

downiorce l ike shows on Figure 2.8, and hence improve the performa nces of the ca r

[12].

a

WV

a t b w s

ar low t o s t a y

t

y a t c h d

: R o u n d t u b h q d i v e r q s

a n d c o J w e r g e

D G

q u k t d y t o p e r n H f o w

t t c d m e n t

Figure

2.7: Type of a irf low [7]


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Figure 2 8:

Aerodyn amic affect [1]

2 4 M aterial

Com m only used m aterial for fabricated a spoiler are f ibreglass and polyester .

2 4 1 F iberglass

Fiberglass also called fibreglass and glass fibre) is material made from

ext rem ely f ine f iber s o f g lass . I t is used as a r e in fo rc ing agen t fo r m any po lymer

produc t s ; the resu lt ing c om posi t e m a te r i a l, p roper ly known as f ibe r -re inforced

polym er (FRP) or glass-reinforc ed plast ic (GRP), is called fiberglass in popu lar

usage [8].


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1

2 4 1 1 Formation

Glass fiber is formed when thin strands of silica-based or other formulation

glass is extruded into many fibers with small diameters suitable for textile

processing. Glass is unlike other polymers in that, even as a fiber, it has little

crystalline structure. The properties of the structure of glass in its softened stage are

very much like its properties when spun into fiber. One definition of glass is an

inorganic substance in a condition which is continuous with, and analogous to the

liquid state of that substance, but wh ich, as a result of a reversible change in viscosity

during cooling, has attained so high a degree of viscosity as to be for all practical

purposes rigid [8].

2 4 1 2 Chemistry

The basis of textile grade glass fibers is silica, SiO

2

. In its pure form it exists

as a polymer, SiO

2

). It has no true melting point but softens up to 2000°C, where it

starts to degrade. At 1713°C, most of the molecules can move about freely. If the

glass is then cooled quickly, they will be unable to form an ordered structure [8].

In the polymer it forms SiO

4

groups which are configured as a tetrahedron

with the silicon atom at the center, and four oxygen atoms at the corners. These

atoms then form a network bonded at the corners by sharing the oxygen atoms,

Figure 2.9 shown the network bond. The vitreous and crystalline states of silica

(glass and quartz) have similar energy levels on a molecular basis, also implying that

the glassy form is extremely stable. In order to induce crystallization, it must be

heated to temperatures above 12 00°C for long periods of time [8].


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oxy

si l icon

Figure 2 9:

M olecular s t ructure of g lass [8]

Althou gh pure silica is a perfe ctly viable glas s and glass fiber, it must be

worked w ith a t very high temperature s which are a drawback u nless it s specif ic

chemica l properties are nee ded. It is usu al to introduce impurities into the glass in the

form o f other materia ls , to lower i t s working temperature . These ma teria ls a lso

impart various o ther properties to the glass w hich may be beneficial in differe nt

applications [8].

The first type of glass u sed for f iber was soda-lime glass o r A glass. I t was

not very resistant to alkali. A new type, E-glas s was formed that is alkali free (


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2

Mo st glass fibers have limited solub ility in water but it is very dep enden t on

pH. C hloride ions will also attack and dissolve E-glass surfaces. A recent trend in the

industry is to reduce or eliminate the boron content in the glass fibers [8].

Since E -glass does not really me lt but soften, the softening point is defined

as, the temperature at which a

0.55

0.77 mm diameter f iber

9.25

inches long,

elongates under its own w eight at 1

mm/min

when suspended vertically and heated at

the rate of

°C

per minute . The strain point is reached wh en the glass has a viscosity

of

W4 5

poise. The ann ealing point, wh ich is the temp erature whe re the internal

stresses are reduced to an ac ceptable comm ercial limit in 15 minutes, is ma rked by a

viscosity of

10

13

poise [8].

2 4 1 3 Properties

Glass fibers are useful because o f their high ratio of surface area to w eight.

How ever, the increased surface area m akes them m uch m ore susceptible to chemical

attack. By trapping air within them; blocks of glass fiber make good thermal

insulation, with a thermal condu ctivity of 0.05 W /mK [8].

Glass strengths are usually tested and reported for virgin fibers which have

just been ma nufactured . The freshest, thinnest f ibers are the strongest and this is

thoug ht to be due to the fact that it is easier for thinner fibers to bend. Th e mo re the

surface is scratched the less the resulting tenacity is. Because glass has an

am orphous structure, its properties are the sam e along the fiber and across the fiber.

Hu midity is an imp ortant factor in the tensile strength. M oisture is easily adsorbed ,

and can w orsen microscopic cracks and surface de fects, and lessen tenacity [8].


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3

In contrast to carbon fiber glass can undergo more elongation before it

breaks. The viscosity of the molten glass is very important for manufacturing

success. During draw ing (pulling of the glass to reduce fiber circumference) the

viscosity should be relatively low. If it is too high the fiber will break during

drawing, however if it is too low the glass will form droplets rather than drawing out

into fiber [8].

2 4 2 Polyester

Polyester is a category of polymer or more specifically condensation

polymer, w hich contain the ester functional group in their main cha in. Usually,

polyester refers to cloth woven from polyester fiber. Polyester clothing is generally

considered to have a less natural feeling to it compared to natural fibers [13 ].

Polyester fibers are often spun together w ith fiber cotton, producing a cloth

with some o f the better properties of each. Because there are so man y varieties of

plastic, and new ones are being deve loped almost continuously, it is helpful to have

knowledge of both general properties of plastics as W ell as the unique or specific

properties of the various families [1 3].


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4

Gen eral properties include:

i

ight weight

Most plast ics have sp ecific gravities between 1.1 and 1.6,

com pared with about

75

for magnesium (the lightest engineering metal).

ii Corrosion resistance:

Many plastics perform well in hostile corrosive

environments. Some not notably resistant to acid co rrosion.

iii

Electrical résistance:

Plastics are widely used as insulating materials.

iv

Low thermal conductivity:

Plastics are relatively good thermal insulator.

V

Variety of optical properties

Man y p las t ic s have an a lm ost un l imi ted

colour ra nge, and the colour goe s throughout , not jus on the surface. Both

transparent and o paque materials exist.

vi Surface finish

Excellent surface finishes can be obtained by the same

proce sses that produce the shape. Addit ional surface f in ishing ma y not be

required.

vii

Com paratively low cost:

The low cost of plast ics genera lly applies to both

the ma terial it self and the ma nufacturing proce ss . Plas t ics freque nt ly offer

reduc ed tool costs an d high rates of production [13].

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Hasbullah Bin Mat Isa