Saturday, June 15, 2013

MountainBoard (MB) & MB-Longboard Hybrids: Custom Assmemblies / Builds

MountainBoard-Longboard Hybrid
June  14, 2013

I put this together for my son who has an injured left ankle (4 surgeries).  He loves it ...


Thanks to my SD bruthas MarkBrosnan and Brennig for the wheel suggestions, Bennet Alligators and Abec 11 Gumballs.  My son chose the Abec 11 Gumballs, 76 mm x 75 A.


MBS Jeep Rennegade deck and MBS ATS trucks (15.75" axles).








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Street-Rig MountainBoard Build:  Surf-style Carver
November 20, 2011

Cotton print lam -- Hawaiian hibiscus:
(Tip: iron fabric before lamming with epoxy resin)


Deck surface without fiberglass skin.



Deck with double layer of 4-oz S glass plain weave over cotton print (S-glass is not as clear as E-glass).


Build progression from Baltic Birch Core, Aluminum tips and 6-oz X-Glass + 6-oz Carbon Fiber bottom.
(Bottom was finalized with a 4-oz S-glass outer laminate to improve stiffness).





Custom street-rig MB assemblies built with commercially available components -- for surf-style carving (16" & 18" axles, left and right respectively, with 8-3.00-4 Cheng Shin smooth tires):


Friday, June 14, 2013

Paddle-In Hydrofoil (PIH) Surfboard

PIH Surfboard Ruminations

For a related discussion about "paddle-in" hydrofoil surfboard development, click this link to a thread at Swaylock's Surfboard Design Forum:

http://www2.swaylocks.com/forums/shortboard-hydrofoil-video


Check out these articles by Terry Hendricks (Ph.D.) too:

http://www.rodndtube.com/surf/info/Hydrodynamics.shtml



Scissor-Tailed Flycatcher

This is a quick sketch of my Scissor-Tailed Flycatcher inspired foil concept for a hydrofoil surfboard.  The Scissor-Tailed Flycatcher is common on the rural Texas coast.  



Scissor-Tailed Flycatcher

The sketch was quick, and the Spitfire wing had similarities to the Flycatcher wing.  I think the spitfire wing would be highly responsive for slower/smaller to medium speed/size waves.  I think front foil shape will need to vary with peformance (desired responsiveness) and wave type/speed (mellow shallow angle wave faces versus steep dredgers).
Bird wing shapes differ -- flycatcher versus falcon -- according to needed performance.  Birds can individually alter wing shape too (pulling wing tips in).  I think streamlining (wings swept back) can be used to reduce sensitivity and improve speed.
Apparently the Scissor-Tailed Flycatcher is very agile and maneuverable.
Scissor-Tailed Flycatcher Performance:
"They are agile in the air, spreading their long tails wide to make abrupt turns and stalls.
The tail proves useful as they expertly catch insects on the wing with sharp midair twists and turns.
The Scissor-tailed Flycatcher flies in straight lines with fast wingbeats, its tail folded. It also often hovers with its tail spread or makes abrupt turns in midair."

Surfboard for Hydrofoil Experimentation:


Version 1.0:  Cardboard Mock-Up of Twin Foil PIH, 06/30/2013  (revised design needed):

Below is a conceptual, full size cardboard mock-up (yardstick underneath) of what I was seriously considering at the middle of last week, 6/26/2013.  This weekend I decided it needs significant re-design.  Total foil surface areas are calculated to lift 84 kg at 2.5 sq. in./kg, total area adjusted for angled foil surfaces.
The front wingtips for this design would be angled significantly downward at the black lines marked on the foil -- tips not angled in picture.  Wingspan of the front foil is 21" with tips not angled downard.  The horizontal section is the low velocity secion.  In theory, the down-angled tips are the progressive velocity portion for higher speeds.  But I am certain the rear stabilizer foil would hydroplane at higher velocities.  (Maybe a hydrofoil-hydroplane hybrid would be something worth exploring).


According to Brett Curtis (in Oz), you need somewhere between 2.5 - 3.1 sq. in./kg at ~ 3 mph (5 kph) for lift.  Quarter this for each doubling of speed.  However, you need the larger surface when you take off to initiate lift at low velocity.  As velocity climbs, you need less surface area.  This is why we want progressive velocity foils that reduce surface area and remain stable as speed increases.

As Brett mentioned elsewhere, the quadrupling effect comes from a standard lift equation.  Swied proved it in one of his posts:
Swied quote: 
It follows right along with the lift equation that I posted above.
Here is the equation again:
         L = (1/2) d v^2 s CL  
The density of water, the surface area of the foil, and the Coefficient of lift remain constant, so the equation can be simplified as...
          L = a * v^2
where L = lift force, a = constant, and v = velocity
Say you are going 3 mph, then L = a * 9.  If you double your speed to 6 mph, then L = a * 36.  There you have it: 36/9 = 4.  Doubling your speed quadruples lift.
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Elliptical vs. Angular Tips, 07/04/2013:

I am thinking a front foil with down-angled, elliptical tips (below) is closer to what I want (symmetrical).  Elliptical tips have much cleaner lines than parabolic tips. They give me some streamlining, and more area to work with than triangular or trapezoidal tips.  And I can still have a rectangular, low-velocity horizontal foil section between the down-angled tips.



This is a graphic I made with ellipses and a rectangle using Microsoft PowerPoint.  I was just playing with the shapes and dimensions until I got something that looked right -- no specific design objective.  If I scaled this particular foil (wing) up, it would be 6" x 27" (15.24 x 68.58 cm) with a "flat lift area" of 143 sq. in.  But with down-angled tips, it would have an "effective lift area" of 122 sq. in.  Using only PowerPoint, I can print a full-size and precise template. (BTW I do not  mean to imply PowerPoint is an ideal graphics design program.  I have it readily available, so I found a way to use it.)

The following are foils with elliptical tips and elliptical foils.  All foils pictured have the same surface area but differing chord lengths (leading edge to trailing edge), 07/06/2013.


Foils with Elliptical Tips






Elliptical Foils






Angular vs. Gravitational Acceleration:

Just a quick comment without elaborate discussion:
What I like most about 45 degree down-angled foils is that vertical and horizontal lift vectors are equal (have the same magnitude).  They also can be surface-piercing, asymmetric foils with symmetrical outlines.
The greatest lift force is perpendicular to the bottom surface of the asymmetric foil.
With 45 degree lean angles (or greater), centrifugal/centripetal acceleration may be a more important consideration than gravitational acceleration.
Earth's gravitational acceleration is 32 ft/second per second.  Times 3 = 96.  So if my calculations are correct, a turn with a fixed radius of 10 feet at 21 mph will produce a centrifugal/centripetal acceleration of 96 feet/second per second.  Apparent rider/board weight will be 3 times greater than stationary (gravitational) weight.

Sunday, January 9, 2011

HOTWIRE FOAM CUTTER POWER SOURCE / SUPPLY & WIRE 

The material below is intended as information for learning.  It is not a recommendation to build your own hotwire power source/cutter.  If you do not understand the physics of electricity, and the associated risks/danger, it might not be a good idea to build your own hotwire cutter.

I spent over 8 weeks looking for information on the internet that I would need to build a hotwire foam cutter, using a 6v/12v car battery charger. I have consolidated the useful information I learned below.  I have updated some of the information and links since I first wrote this blog post.  If you plan to use an automobile battery charger, it must be a "manual" charger.


There is more information online about using nichrome wire for hotwires -- this is what I discuss below.  I found small quantities of Nichrome wire available online, for reasonable prices, at this site:


http://www.jacobs-online.biz/nichrome_wire.htm

This is a good link for an introduction to hotwire cutters:


http://hotwirefoamcutterinfo.com/Introduction.html

The table at the bottom of this post was generated using the Jacobs Online nichrome caculator.  It provides specific resistance values and temperature/amperage values about various nichrome wire gauges for making general wire length estimates.  The online nichrome calculator gives more detailed, and I will assume, more precise information:

Nichrome Calculator link:


http://www.jacobs-online.biz/nichrome/NichromeCalc.html


These Ohm's Law Formulas may be useful:

Volts = Amperes X Ohms
Amperes = Volts/Ohms
Ohms = Volts/Amperes
Watts = Volts X Amperes
Watts = (Volts X Volts) / Ohms
Watts = Amperes X Amperes X Ohms
Ohms = Watts / (Amperes X Amperes)

V = Voltage (Max for power source)
I = Current or Amperage, Amperes, Amps
R = Resistance or Ohms

V = IR

V/I = R

Divide Voltage by the Amperes needed to heat the wire gauge you have chosen to achieve the desired foam cutting temperature. This gives you the total Resistance needed in Ohms. Then divide total Ohms of resistance by Ohms/ft to get the length of Nichrome (Chromel C) wire needed:

I concluded that with my 12-volt (6-amp) and 6-volt (6-amp) charger settings I can put together a hotwire cutter that is as versatile as a Variac powered unit.  


After reading the information at the Jacobs Online site further, I saw that you do not want to choose a wire gauge that requires the maximum amperage from your power supply. I chose a guage (22) and length that would need no more than about 62% max amperage -- in my case 3.7 amps at 600 F and 12 volts.  The thing that was not clear to me before visiting the Jacobs Online site is that the amperage required to heat a piece of nichrome wire to an exact temperature, for a specific gauge, is constant for that gauge -- regardless of length.  So voltage must change as wire length varies to achieve an exact temperature (e.g. 600 F).

I found that I should get temperatures between 600-800 F by using 22-gauge Nichrome wire, with alligator clips placed from 37 - 30 inches apart (shorter = hotter) with 3.7-4.5 amps (voltage = 12).  A 7-inch difference in length gives a 200 degree temperature range.

For the 6-volt 6-amp setting, 22-gauge Nichrome wire, with alligator clips placed from 18.4 - 15.2 inches apart and the same 600-800 F temp range -- Amperage from 3.7- 4.5 (voltage = 6) -- a 3-inch difference in length gives a 200 degree temperature range.   These values were determined using the Jacobs Online calculator, not the table at the bottom of this post.

The nichrome wire temperature needed will depend on the type and density of foam being cut, and the desired cutting speed. The internet information I found suggested that 600 F is a common temperature for cutting foam with a hotwire. This would be a good starting point -- temperature should be adjusted according to testing results and observations from experience. Be cautious, wires are very hot and can break if the wrong gauge has been chosen. Wear appropriate protective/safety equipment, especially goggles.  Make sure the electrical components (switches, clips, wire etc.) are rated for the amperage your hotwire cutter will be using.




Simple DIY plans for a "low-voltage" variable-output hotwire power supply:

http://www.jacobs-online.biz/power_supply_design.htm


Information about variable rate power supplies:

http://hotwirefoamcutterinfo.com/__Variable.html

Variac power supply:

http://www.circuitspecialists.com/variacs

Hotwire cutter video links (foam press mold cutting):

http://vimeo.com/17137988

http://www.youtube.com/watch?v=m-R__S6U9J0


Simple plans for a hotwire bow or harp courtesy of airframe at Swayocks.com:

(click on image of plans for higher resolution)

http://www.swaylocks.com/comment/164400#comment-164400






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Information about Polystyrene (XPS, EPS) foam types/specifications:

The data in the table below was generated using the Nichrome Calculator at Jacobs Online:

http://www.jacobs-online.biz/nichrome/NichromeCalc.html

The resistance and amperage values/requirements in this table appear to be accurate.  But using these values to calculate needed wire lengths mathematically, as described previously, will give slightly longer estimates than the Jacobs Online nichrome calculator.  I will assume the Jacobs Online calculator is more precise and factors in wire length and resistance increases that occur when wire temperatures increase.