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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]
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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].
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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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