Alloy mustache bar

[waxhead]

I have just been talking with my water jet cutter about making some alloy mustache bars.

I will work on the drawing tonight, it would help if some one had off a car and could give me some dimensions to start off with

Ie distance in drop between the top mounting holes and the diff bolts

[Scoota G]

Got two off at Dalee's place i can get some measurements tomorrow for ya.

[waxhead]

That would be awesome

thanks for that

I have the distance between the main down studs sorted but just the other measurements i dont have

this is the kind of thing i have in mind

basic at this stage but you get the idea

[waxhead]

Im just trying to figure out design ideas at the moment

Im not sure that making it out of steel is not a bad idea and this i can make it thinner with more intricate cuts

[stevo_gj]

If you want me to conduct a stress analysis to compare your various designs I can put them into an FEA package I have. I won't be able to give you lifetime performance results because I can't begin to guess actual fatigue loading conditions, but I can give you data that you can use to compare the designs to each other.

[waxhead]

Yeah that would be awesome thanks for that

What do you need from me , as in what type of file

Maybe we can get a few of these made ??

[stevo_gj]

Anything that can be opened with Solidworks or Solid Edge. Preferably .iges .igs or a .sldprt file. If you can't do any of those give me a list of possible file names and I'll see what I can work with.

 

Email it to stevo_gj AT hotmail.com

 

I am going out to dinner but would be able to have have a crack at it later.

 

Also it would be great if you could draw a small diagram showing the loads you want me to test, just in terms of directions.

[waxhead]

OK will do

Im just trying to get basic dimensions at the moment to help me with the drawing

But will lie under car with tape measure later

[waxhead]

Ok i like this design better

Been underneath measuring the bar but i really need one to trace out on paper to take more accurate measurements

Its 12.5 mm wide and I just have to draw up the bush mounting brackets easy!!!

[waxhead]

OK mounting bracket done

Its close in dimensions will just have to move a few bolt holes around when i get the finial details but it would be with in 10mm of correct

[waxhead]

Ok sent you an email

 

[Mr Camouflage]

Looks a bit like the Arizona Z car mustache bar

 

http://www.arizonazcar.com/azcM2487.JPG

[waxhead]

Its kind of hard to make them look to much different if your water cutting them out of alloy

But yes i was using there pictures for ideas on the drawing

[Mr Camouflage]

I just noticed that the AZ bar doesn't have holes in it. The holes are just milled recesses.

 

Here's a better picture.

 

http://www.classiczcars.com/forums/attachment.php?attachmentid=5966&d=1096246919

 

Would be interesting to see the stress results Stevo will be doing with a bar with holes compared to one without.

 

[stevo_gj]

Hey guys, I'm gonna post here what I emailed Wax:

 

"Hey mate,

 

 

My professional FEA software (Strand7) is on the fritz on my PC, so I've used Simulxpress which is a small FEA package within solidworks. I've applied 1kN on each of the bolt holes for the diff, which is an overestimate of forces involved, and then restrained the two large bolt holes on either end.

 

Since I do not know the size of the forces involved I am not able to give you accurate figures for the stress, but I will be able to use the ‘guessed load’ to qualitatively show you the highest stress areas. This will allow you to compare one design to another by applying the same load and see which has the highest stresses.

 

In other words, the stress analysis is only useful if you have more than one model for me to test. Knock up another design when you get a chance and I'll apply the same loads and see how it compares.

 

Cheers,

 

Steve"

 

I've attached the results of the FEA.

[gav240z]

Pretty impressive stuff guys. I'm thinking we need an Auszcar online store so when parts like this are available you can easily sell them through the club store to anyone anywhere in the world.

[Mr Camouflage]

Maybe try a rotational force to the center bolt holes that hold the diff to simulate the torque of the engine.  Maybe one force up and the other force down.  Not sure what other forces would be involved.

 

 

[waxhead]

OK i will do a mirror image and shove the block on the other side so you can hold it there as well

Also i will increase reduce the gusset on that hole to leave more  metal there so it will be stronger

there is also a torsional force on this part as the top bolt holes are held the bar tries to twist up

 

Mr camo man

I need to get it right with the holes in there as its a water jet job and as such they cant do depth

I suppose i could do it with out holes at all but it wouldn't look as trick

[chris240]

top thread guys 

how many other autocad operators do we have here  Im not too bad on 2d, but using 3d / revit etc is outa my league !

[stevo_gj]

Hey guys,

 

I will change the loading conditions to reflect the torsional force involved. Which alloy were you going to make it out of btw? I need to choose a metal and so far I've just chosen 1060 aluminium alloy.

 

Eww simulxpress doesn't let you show the stress contours without showing displacement, so I have to show you the deformed model...

[waxhead]

was going to go for 6061 or maybe just 5000 series

this depends on the results of your tests

[stevo_gj]

So I was thinking about how we can actually estimate some of the loads involved in this bracket, however without access to testing equipment and data I can only use rough figures...

 

I think if we picked the maximum torque than an L Series motor is capable of producing at the drive shaft and then tested that torque acting entirely through the two bolt holes we would get a benchmark figure that we could say was a 'worst case scenario'.

 

So what I need to know is: what is the max torque that a high end L28 is capable of producing (at the driveshaft)? Ballpark will be ok.

[zedevan]

alternatively you could always do a rough model estimation of the AZC mustache bar, and see what force it fails at to use as your benchmark?

 

how many other autocad operators do we have here

i'm a cad monkey, jump onto solidworks sometime and watch a few tut's on it on youtube and u should go fine. its only downfall is it craps itself to easily...yet sadly its still my prefered program

[stevo_gj]

Yeah i was thinking that Evan, that would definitely be the best solution. However it would require me to know the dimensions of the bracket and materials it is made from, which is probably very difficult to get.

 

If someone wanted to provide this information we would be very very grateful (hint hint)

[waxhead]

Its made from 6061 and its half inch alloy

I think the major issue you would have is if you had a worn front mount

The front mount should take the majority of the torsional load

I'm still waiting on exact dimensions to finish it off then off to the water cutter