WF01

Sports Car

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 their category. The chassis philosophy is more similar to LMP car than Sport Prototype Car class.

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Challenged both by the project’s complexity and the stringent deadline, AXIRO 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, to enable subsequent manufacturing and homologation phases, and eventual racetrack testing by the end of November 2009.

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

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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.

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In order to maximize accessibility throughout the diverse phases of intervention, fixing or set-up, the various bodywork parts are divided into subassemblies.

The removable front cover 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, to allow enough space to make, directly into the chassis, two fuel filler openings, one each side, studied for endurance races. Chassis shape continues on roll-bar fairing without discontinuity, cleaning airflow directed to rear wing.

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Chassis

Chassis of the Wolf GB08

The heart of the car, this component fundamentally originates as a really innovative element for the vehicles of this category. The objectives were torsional and bending stiffness, 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 up 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 operative conditions. 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 “downforce”, 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 car racing, 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.

Aerodymanics
Suspensions

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. For this purpose the crash test was needed, even if all the other checks fully satisfied norms and regulations, above all to give a full value to the computer simulations we made, confirming that way AXIRO’s methodological effectiveness.

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Tools

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

* The choice of the tools used in this project was determined by the client. AXIRO uses various software for both simulation and modeling and can adapt to client’s choices.

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

AXIRO operates across four major market sectors and provides multidisciplinary engineering and consultancy support to deliver effective solutions and products to our customers.

Contact us

AXIRO ITALIA

Via Ignazio Silone 81

24059 Urgnano BG, Italy

+ 39 035 315 165

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