Conceptual design and numerical validation of a composite monocoque solar passenger vehicle chassis

Denny, Jason; Veale, Kirsty L.; Adali, Sarp; Leverone, Fiona

doi:10.1016/j.jestch.2018.07.014

Cited by 13 publications

(8 citation statements)

References 14 publications

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“…It was to be used to mount the suspension system of the car, which carried the most load. Following the calculation process given in [29], the weight of all components (chassis, battery, and mechanical systems and electronics) was 35 kg, and the driver was 50 kg, and together with 3 g acceleration yielding a load of approximately 1000 N. Therefore, Type C hard point with failure load measured at 1300 N can be used to safely support the load of 1000 N.…”

Section: Simulation Results and Discussionmentioning

confidence: 99%

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Mali

Hussain

HASSAN³

et al. 2022

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Composite sandwich panels are widely used in lightweight structures, especially in aerospace, automotive, and marine industries. They are chosen mainly because of the superiority of their specific stiffness as compared to solid panels. Stingray, a solar car designed by the UiTM Eco-photon team, applied this technology for its lightweight property. However, the honeycomb sandwich constructions were susceptible to localized load. Thus, load attachment points using metal inserts, also known as ‘hard points’, were introduced. In this study, the behaviour of hard points based on three volume variations of the potting agent was investigated. ESA recommended static pull-out tests to be conducted on the sandwich panels composed of Nomex honeycomb core, two laminates of carbon fibres/epoxy composite as the face-sheets to determine the failure load of the hard points. A finite element simulation using ANSYS was also performed to determine the displacement of the inserts in presence of normal-to-plane load. The results include load versus extension curves obtained by both methods. Potting agents were found to elevate the stiffness and the strength of the inserts by some degree. Therefore, the application of these hard points on the solar car was found to be effective.

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Section: Simulation Results and Discussionmentioning

confidence: 99%

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Mali

Hussain

HASSAN³

et al. 2022

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“…The core is typically a low-strength material of high thickness, providing a sandwich composite with high flexural stiffness at low overall density. The sandwich-structured composites have been utilized on the body of vehicles in student car competitions, such as the student solarpowered cars [10,11], and student racing cars [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

“…Several studies explained how the monocoque composite design process was carried out using analytical [15], experimental [12,13,16], and simulation methods [11,[17][18][19]. A combination of experimental and simulation methods was carried out for the suspension connection zone of the monocoque chassis [20].…”

Section: Introductionmentioning

confidence: 99%

Design and Fabrication of Composite Monocoque Chassis for Formula Student Racing Car

Wikarta

Maydiyanto²

2023

JMES Int. Journal of Mech. Eng. Sc.

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This study used a combination of analytical, simulation, and experimental methods to design a sandwichstructured composite monocoque chassis. The analytical method, which determined the stiffness value of the composite, depended on the number of layers and the orientation of the fiber angle. The simulation method, based on the finite-element method, was used to validate the stiffness value. The experimental method involved a 3-point bending test that was used to verify the effectiveness of the design produced by analytical and simulation methods. After all model designs were validated through simulation and experimental methods, the next stage was monocoque chassis fabrication. The stiffness and strength were achieved with variations of combined layup orientation angles of 0 • and 45 • , which could be applied to all panels, regardless of the number of layers. Based on the design results, the processes involved in fabricating the monocoque chassis began with the manufacture of molds and the layup of carbon fiber. Afterward, the prototype was inserted in the oven and the final product experienced finishing to prepare it for use. The fabricated monocoque chassis was used in 2 events in Japan's annual Formula SAE student racing car competition.

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“…Basing on the results the Computer Aided Design (CAD) models were made together with structure analysis using Finite Element Methods (FEM). Usually at first it is beneficiary to prepare concept design and test it using FEM methods which accelerate the design process significantly as it has been done and reported in [12][13][14]. Moreover, the importance of manufacturing process must not be forgotten as it equally if not more important for the design to be properly made as well as cost and time effective.…”

Section: Introductionmentioning

confidence: 99%

Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

Rządkowski¹,

Klik²,

Tracz³

et al. 2022

Adv. Sci. Technol. Res. J.

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This case study describes a manufacturing process of composite chassis also known as monocoque. The structure is made using carbon fibre reinforced polymers (CFRP) which are manufactured in out-of-autoclave (OOA) process from pre-impregnated carbon fabrics and aluminium alloy honeycomb core. Since the material cost is high the aim of the project was to reduce the cost of manufacturing process i.e. cost of models and moulds. Therefore, instead of high-temp models and moulds a cheaper alternative was used. It consisted of Styrofoam models made using polyurethane (PU) paste and moulds made from CFRP using wet layup process which were cured at room temperature. Such moulds had to be adapted to withstand high temperatures during pre-preg cure. This was done with gradual heat annealing process which increased the maximum service temperature from 45°C to 90°C. This was enough for the low-temp cure of pre-preg material, but it might be possible to increase the temperature even further. As a result, the cost of manufacturing process had been reduced by 50%.

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Conceptual design and numerical validation of a composite monocoque solar passenger vehicle chassis

Cited by 13 publications

References 14 publications

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Design and Fabrication of Composite Monocoque Chassis for Formula Student Racing Car

Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

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