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Reverse engineering of auto parts for a Matra jet 6

Having a great attraction for the automobile and wanting to develop my skills in this field, I chose this project at the end of my first year of BUT. I had never heard of reverse engineering before, redesigning and manufacturing parts of an old race car appeals to me a lot. I want to be able to add my stone to the building, in order to make the car as efficient as possible.

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Currently, I am working on this project for a period of 2 semesters at the IUT.

My team consists of 3 people supervised by a project tutor.

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At the beginning of September 2022, we had our first project session, where we met our client Mr.Comelli. After getting to know him, he gave us our first order aspeed plate cylinder with specifications. The part makes it possible to maintain a rubber gaiter of the gear lever and to guide rotating parts allowing the rotation of a rod in contact at the other end with the gearbox of his car a Matra Jet 6._cc781905-5cde -3194-bb3b-136bad5cf58d_

speed plate cylinder

This part had already been machined by students from last year, but it lacked drilling, tapping and chamfering the part to make it slightly cylindrical. I decided to orient myself on the manufacturing part, to do this, I wrote the manufacturing range and helped to realize the CAM of this part.

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Cylinder

Platinum

Old original set

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Dimensional drawing provided by the customer

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Tapping

Through hole

Chamfering

Set already machined

Range of manufacturing

​ I first analyzed the CAD of the finished part and then I started thinking about the necessary machining steps. After that, I was able to write the manufacturing range by choosing to machine on the VF1 (4-axis machine) to be able to perform the through hole. We also had to think about positioning the part for machining.

Visit to the customer on October 13, 2022 to see the layout of the different parts ordered and understand their operation.

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Machining of the return finger for a Matra Djet in 2 phases

Phase 20: Surfacing

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speed board

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Spacer

Tapered ball bearing

- double row

Installation in the hub carrier

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hub carrier

Having encountered various problems such as our tool order which did not arrive, our client decided to give us another order, the manufacture of hub carriers. They support the wheel to make it easier to turn. They host in their centers bearings at each end, wedged between them, through which the rockets pass. After a phase of analysis of the specifications then disassembly of the hub carrier. We scanned the room with a 3D scanner. We then took measurements of the part using a CMM (three-dimensional measuring machine), which allowed us to model the part in 3D. While looking for blanks on the Internet, we realized with the customer that the cost price of the part would be expensive, so he decided to cancel this order. He finally asked us to rework the two original hub carriers, in order to readapt the guidance system. It was therefore necessary to apply some modifications to the basic system: machining of the bore already present, modification of the spacer and the type of bearing (a single tapered bearing with double row of balls instead of 2 before). I took care of modeling the spacer in 3D, but having to wait for a member of my team to finish the complete modeling of the hub carrier, I decided to take care of another customer order. So I still have to do the manufacturing range, the phase contract, the CAM and machine the part.

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Scan of the room

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Measurement on CMM

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Part being scanned

deflection finger

I decided to take care of the customer's third order, a return finger in contact with the speed cylinder, allowing the creation of a ball joint between this part and a spherical end shaft which will be useful for the ball joint of the gear levere.

There were no real specifications for this part, just a dimensioned drawing and information transmitted orally by the customer, he wanted a series of around 8 - 10 parts. 

 Design

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Reproduction of the dimensioned drawing in CAD with the addition of fillets to reduce the size of the part.

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Part CAM

For the manufacture of this part, there was a problem at the manufacturing level, it could not be machined, because the tools would have touched the jaws of the vice. So I chose to do a standard machining which consists of having a stock height greater than the initial height, machining then turning the part over and surfacing to remove the extra thickness.

Choice of:

  • Machining operations

  • Tools

  • Cutting conditions

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Stage 10

Stage 20

Machining on a 3-axis milling machine

(Diameter 300)

  • Measurement of tool gauges

  • CED calculations

  • Assembly of tools

  • Inserting the program into the machine

  • Vacuum machining

  • Stock abutment

  • Machining of the part

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Stage 10

Stage 20

Finished part

  • Measurement of the part to check if the dimensions are within the tolerance interval

  • Correction of tool gauges

  • Machine the part by applying tool gauge corrections

  • Repeat the previous steps until you obtain the desired dimensionses

​ This project allowed me to discover new machining processes (standard, modular assembly) and to understand the function of several car parts. But also, what should be their characteristics (geometry, material), in order to improve the performance of the car.

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