Niall Carmichael

SID: 3678417
Unsprung Masses
I would like to be involved with the unsprung masses group as I believe it matches my skills and
previous experience best.
While on placement I was required to design and machine welding jigs for a new generation of
fabricated upright. The jig included removable components which allowed vital hard points and
surfaces on the uprights to be milled/drilled to compensate for expansion/contraction during the
welding process.
Along with the new uprights were new hubs which allowed for a new floating disc arrangement. I
was involved with the design of these and was in charge of liaison with the brake disc
manufacturers. I wrote all of the machining routines for these and operated the mill. I had to design
a fixture for a final turned operation on the hubs, which kept the bearing surfaces in relation to the
wheel studs.
Due to my hands on experience in motorsport as well as design I can identify/specify all threads
metric or imperial by eye and can read NAS bolt codes. I feel this would be useful to a team as there
will inevitably be rose joints and NAS bolts.
I have done a lot of carbon fibre layup and mould design as well as the hands on lay up of the
prepreg and I feel this may be useful to the wheel centres. I also have access to a 1.4m diameter
autoclave.
So in conclusion the reason I think I am most suitable for the roll is because I have been designing
parts for a year, but not only designing having to consider how it will be manufactured and how that
will affect the design. I used a substantial amount of FEA for the design of the hubs.

Upright Jig

Upright Jig Assembly

Hub

Vehicle dynamics
I am also interested in the vehicle dynamics group as I have been involved with vehicle setup over
the last year. I havent necessarily designed any different geometry but have changed camber and
toe within their adjustable ranges and understand what change could be expected in drivability,
overall grip etc.

I have done a lot of data analysis using MoTeC i2 Pro and DTASwin and am able to visualise what
loads or travels mean.
The vehicle ride section of this project is interesting to me as my individual project is to design a
servo for adjusting Ohlins 4 way adjustable dampers, so feel this may help my contribute to both
projects.
I have used ADAMS just in my spare time for a go kart I am designing so am not majorly confidant
but do have an understanding of how to use the software.
As well as the upright jig mentioned earlier I have also designed and machined new wishbone jigs, as
well as machining steel tube intersections from CAD to get perfect fish mouths to allow for perfect
welds, this may well be relevant for a new wishbone design and manufacture.