Steps of Manufacturing The Steering Wheel
Introduction
Steering wheels nowadays are made up of resin covered metallic internal core and an external shell that is made up of different material depending on the manufacturer (George, 2011). In this formula model car steering wheel, the core will be made up of carbon fibre that will be impregnated with polypropylene. The rack housing will be made of 6063-T6 high strength aluminium with the grips being ABS.
Steps Followed in Manufacturing of Steering Wheel
In the present technology, the internal metal core designated 4, is comprised of the external rim 3 and spokes 2 (Karnopp, 2003). The steering wheel parts for formula student are CNC stamped and the composite materials making the shell will comprise of aluminium 6063-T6. Steps to be followed are as outlined;
1. The pile of aluminium sheets and composite materials 7 are hot moulded in an in a mould 8 that has a cavity 9 with a suitable shape and a cover 10 that has a protrusion 10 whose shape is complementary to the cavity 9.
2. The composite materials 7 are of various thicknesses whereby, resin (polypropylene) is 0.1 to 0.6 mm, the middle sheet 0.8 to 1.1 mm and the external sheet is at 0.1 to 0.8 mm. The three layers will produce a half shell of 1.0 to 2.5mm.
3. The aluminium is impregnated with polypropylene before moulding to strengthen it.
4. Moulding is performed at a temperature of 120 and 180oC. The hot moulding process takes between 1 to 3.5 minutes to be complete. The pressure applied during moulding is dependent on the air amount left between the two shells.
5. Half shells obtained after the moulding process has a part 12 which is a curved central part, and a pair of lateral fins 13.
6. The pair of lateral fins is la...
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...pproximately £72.37. The cost may vary depending on the shipping cost of procured materials and other miscellaneous costs.
Companies Manufacturing Steering Wheels for Formula Students
According to Thomas Publishing Company (2014) companies involved in commercial production of such steering wheels in the United States are; McLaren Automotive, Azusa engineering Inc. – Covina CA, Johnson Bros. Metal Forming Co. – Berkeley, IL. Fiber Dynamics, Inc. Wichita, KS and Stainless Steel Direct – Tillsonburg, ON.
Conclusion
To make a steering wheel for formula student, it must be light, strong and durable. 6063-T6 high strength aluminium is most suited to make the core of the steering wheel. polypropylene is added as a resin to strengthen the composite materials. Manufacture of the steering wheel is an expensive process and is carried out by several companies in the country.
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