Manor MNR1 - Ferrari (aka 2015 Marussia)

[andylaurence]

Also just to mention, the auction so far hasn't featured much from the model (Just the 2015 car), in storage (in the chicken shed as it was called) are 100s of boxes full of 10 of thousands of model parts from several years of wind tunnel running. But I would think that it would be exceptionally hard to make a complete model from theses box's unless someone bought all of them (several vans worth of boxes to put it in context). If these go up in auction and are sub divided and you are tempted, just buy it at face value as a cool box F1 wind tunnel trinkets as putting them together as a total model would be a mission!

Actually, the hundreds of boxes were sold in the last auction. I missed out during the bidding, but had a good thumb through them beforehand. I only have one darkened photo of the boxes of bits (should've used flash):



Here's some photos of the 2015 diffuser showing the pressure taps (circled and numbered) corresponding to the brass connectors on the leading edge:





Readers of Racecar Engineering might recognise this photo from the current issue:


Here's the underside of the front wing:

[PlatinumZealot]

How are the radiators represented in the model? Do you use real mini radiators?

And I have always wondered: are things like, tie rods, brake disks, bearings and screws and drive shafts represented as well, or only just the general surfaces of the car?

If you look back on page 4 you can just about make them out. You can see 2 sidepod inlet with ducting to the radiators each side of the engine cover. The radiators are made from 3d printed SLA i think, made in one shot so theres no glued joints or anything so the are quite large components. The design usually has a multitude of pressure taps printed within the structure so results across the face can be analysed. There's usually a large slot down the side of the radiator that spans the whole face, this is so stainless steel gauze that are glued to a thin metallic frame can be fitted to the radiators to represent accurate blockage. The slot in the radiator is usually big enough to fit 3-5 layers of framed gauzes so the blockage can be tuned.

So no they are not real mini functioning "radiators" but they are accurate aerodynamic representations and have the ability to be tuned with feedback from CFD and the real car data.

The entire brake area is pretty detailed, disks are very accurately modelled, every single drilling on the full side disk is represented at model level including entry and exit ducting, you can even make out the rim seal on the model dustbins.

Drive shafts are representative and kinematically correct but they dont rotate with the wheels, in fact the the entire suspension system is very close to the kinematics of the full size car with regards to the wishbones and the pushrods, but there are a few exceptions due to the packaging constraints of the model but the errors are minimal and strategically designed to be in insensitive areas if they cant be avoided. (For example the blisters over the front suspension chassis end pushrods would not be on the full size car as the suspension system is much more complex that just a pair of bellcranks and packaged within the chassis, but on the model with limited space thats also competing with the steering motor mechanisms this is the best compromise).

So its not just the general surfaces, its a lot more detailed. Even the exhaust is functioning with compressed air coming out of the tail pipe.

Thanks. Now I get an even clearer idea why tunnel testing is so expensive! =D>
Wow... all of that aerodynamic analysis just to be competitive, eh? just wow.

[Blackout]

Actually, the hundreds of boxes were sold in the last auction. I missed out during the bidding, but had a good thumb through them beforehand. I only have one darkened photo of the boxes of bits (should've used flash):

https://farm8.staticflickr.com/7511/159 ... 850168.jpg

Here's some photos of the 2015 diffuser showing the pressure taps (circled and numbered) corresponding to the brass connectors on the leading edge:

https://farm8.staticflickr.com/7462/158 ... f9eb87.jpg
https://farm9.staticflickr.com/8630/159 ... f2218b.jpg
https://farm9.staticflickr.com/8671/153 ... 14e1e4.jpg

Readers of Racecar Engineering might recognise this photo from the current issue:
https://farm9.staticflickr.com/8653/158 ... 21369b.jpg

Here's the underside of the front wing:
https://farm8.staticflickr.com/7536/158 ... 871841.jpg

Do you have some pics showing the interal parts of that model?

[andylaurence]

No, I didn't take many of the models. The 2015 car was laid in bits on the table. I took some of other bits though...

Whole rear end:


Clutch fitted to input shaft on gearbox:


Sensor loom on top of gearbox:


Front of monocoque:


Pedal box loom:


Rear of monocoque:


Underside of sidepod:


3D printed full size upright:


Power steering test unit (that's a Lynch motor on the top):


Vehicle sensor placement:


Some sensors:






I've got some more photos I'll dig out later.

[andylaurence]

A full size mock-up monocoque:




Some schematics of the car electronics:

[andylaurence]

More 2015 parts to discover

[andylaurence]

The 2015 car was internally known as 115M. Quite some work was carried out, with several nose iterations making it to the wind tunnel, mainly focussing on front wing pylon development:



Initially, the nose was quite conventional:



Later iterations moved to a nose with lower turning vanes and this iteration appeared to have been knocked up on the fly in the wind tunnel:



Apologies to the engineers who slaved over these parts that I've quickly stuck together with sticky tape.

[andylaurence]

The diffuser received quite some attention too. Six iterations shown here in chronological order with the first in the top right, last in the bottom left (rows then columns). Don't ask why it's ordered like that!

[andylaurence]

The 115M roll hoop is an intricate piece:



Note the upper intake for the engine and the lower intake for the intercooler:



These pressure taps allow the team to measure air pressure before and after the simulated intercooler:



It's a poor photo, but you can see the internal airways from those pressure taps that are 3D printed into the part:



These pieces slide out the side of the simulated intercooler. They are thin gauze that can be swapped out to vary the pressure drop provided by the intercooler:



There are turning vanes to help the air navigate the turn into the intercooler:

[Richard]

Thanks for the pics Andy.

Apologies to the engineers who slaved over these parts that I've quickly stuck together with sticky tape.

Must have been fun piecing together the jigsaws! Can you imagine going into Sotherby's and asking to borrow some tape to stick a head or arm back on a greek statue?

[andylaurence]

It is indeed great fun. This isn't the end of the thread though. I'm about to crack open another box. All the pieces appear to be 3D printed using SLA. The outer surfaces have all been finished by hand and some marks are visible from this process.

[michaelclarke]

Hello everyone, let me introduce myself as an ex member of the Marussia design team.

I thought as I am no longer under contract with Marussia or Manor I would reply to some of the questions posed on this forum. Im not going to spill all the bean, just correct some of the rumours as many of the staff were quite proud of the windtunnel model and the design direction the car was heading in.

The incomplete Marussia 2015 Formula 1 car design has been revealed after the teams financial collapse. Shown here as an incomplete wind tunnel model the car which would have been called the Manor MNR1-Ferrari carries over much of the 2014 design.

This car is almost complete, the wheels and a small section under the nose are removed ready to place the car in its transport box to McLaren's wind tunnel.

New rules being introduced for the 2015 season mean that the nose structures of the cars have to be reworked and the Manor-Marussia solution is clear to see on this scale model. Compared to the 2014 MR03 the front of the chassis is lower and as a result the front suspension pushrod mountings have created blisters on the upper surface of the tub. A new front wing endplate design is also evident.

The blisters on the chassis are only for the model and is a compromise due to packaging constraints of a 50% model and stuffing it full of sensors and motors to drive the steering, the real car would not have had these.

Manor MNR1At the rear of the car the 2014 concept has largely carried over with the much copied Y-Lon rear wing support. The wing itself is updated compared to the last version seen on a Marussia MR03 (in Sochi), the endplate now features Ferrari style strakes on its outer edge and twin vents on the leading edge instead of the single vent seen at Sochi.

The Y-Lon and monkey wing is actually the same as MR03 as this stage of testing, new designs of rear wing supports and monkey wings were designed and due for testing including a "Yuan-Lon".

"It is conceivable that Marussia had intended to modify its MR03 chassis to meet the new for 2015 rules in an attempt to reduce costs, which highlights the amount of similarity seen with the new design, but also its likely that the Marussia engineers were utilising the same model used for the 2014 design for the 2015 work."

The chassis was going to be all new and was in early production, the surfaces on the upper and lower sections of the nose are very different to MR03. Also the new chassis (known internally as MR04) was several hundred mm shorter than MR03, this was accomplished using a shorter and taller "fuel tank" area of the monocoque. This area of the chassis was quite neatly packaged as above it sloping off on each side were 2 rhomboid shaped heat exchangers feeding from the roll hoop via a Y shaped duct.

"Is it a 50% wind tunnel model?
Or smaller?"

Correct the model is 50% scale.

The second section of the nose seems to have a 'T' shape, (not a simple rectangle because it looks too thin to me).
But it seems they kept the same dimension as the 2014 finger nose for the first section.

Correct there is a keel running under the nose.

Question that may raise then
is, was Marussia effectively over before Japan already or did the test results / windtunnel results for this 2015 prototype
made them decide they've invested and spent money to no luck and it's better to stop effective immidiately?
I like to see varying designs on the 2015 noses, this one is interesting though - but is it practical and effective?

Development of the MR04 started long long before Japan. The wind tunnel model was running in the tunnel back in the early summer, initial design work done back in the spring. MR04 was quite far ahead in terms Cl than MR03 you've seen on track and still a fair bit ahead of the best wind tunnel development of MR03. There was a large update package designed for MR03 that looks like a cross between the car you've seen on track and this wind tunnel model.

That said, am I wrong or the lower part of the chassis below the suspensions is completely missing?

Correct a piece of chassis is missing ahead of the mid barge boards. This section need to be removed for transport within its travel box so a structural piece of the spine of the chassis can be supported, also hence no wheels. The MR04 model was scheduled to be transported to McLarens wind tunnel the day the vast majority were made redundant by the administrator.

I see the little air intake on the airbox is gone.

Yup, that intake was for cooling on the MR03 and quite a late edition. Not for any funky aero like a F-ducts etc.

It seems to me, or the car is shorter?

Yes, see above.

Thats about as far as I want to explain things right now, still seems slightly odd talking about it on here but as i've mentioned myself and the rest of the people involved with the team were really proud of MR04 and the direction it was heading, we felt for sure we would continue our advance up the grid.

Also if anyone from McLaren is reading this i would get in contact with the administrators currently running Marussia/Manor about retrieving the leased equipment (if you've not already) such as the over head model strut and control systems that can be seen in these photos, i would really hate to see that get weighed in for scrap.

And finally i'd like to thank all the forum users here for scouring the internet for photos every GP and digging up all the little easy to over see aero details changes, we do read what you write! Keep up the good work!

This was amazing to read! Like others here I was devastated to find out about Marussia's demise, on balance they were my favourite team last year. To do what you guys did with little budget was a huge achievement.

I remember form the pre-season testing in Jerez you were running little pieces of string near the back of the floor to visualise the airflow, old school . Obviously, shortening the chassis was important for a few reasons, but I liked that extended look; Jules sitting out nearer the front of the car, also kinda old school I guess.

I actually applied for the junior aerodynamicist role at Marussia, just before the news of administration so I felt partly to blame haha.

Also, it goes without saying, I'm still thinking about Jules. What a talented driver.. that drive at Monaco was something else.

tl;dr - you guys were great, sorry to see you go.

[andylaurence]

This is where it gets tricky to piece things together. All these parts are marked floor, but I can't piece them together! Answers on a postcard...



I think this is the only other 2015 diffuser central section (I previously posted the other one photographed at the auction) and this makes 8 different outer diffuser iterations, excluding minor strake developments. You can see how the pressure taps are connected from the outer to central diffuser sections. The gaps are sealed with small o-rings.



Here's the whole diffuser in one piece:




The front wing saw some development too. Clearly there were 15 iterations of these parts, although I've yet to find the previous 12:






I can't work out where these winglets are positioned. They're marked as monocoque parts and there's 11 iterations here chronologically from top to bottom:

[techF1LES]

Some excellent pictures of Marussia MR03 monocoque pre-production mock up in this eBay listing:
http://www.ebay.co.uk/itm/Marussia-F1-2 ... 259effd9e8

[WaikeCU]

If you think about it, 3D printing seems fairly easy to produce to mock up a wind tunnel model of the car by the looks.