CARBON FIBRE COMPONENTS IN AUTOMOBILES

CONTENTS
Introduction Types of carbon fibre sheets used in automobiles Types of carbon fibre components in Automobiles Comparison of carbon fibre parts with Al alloy parts Manufacturing of carbon fiber parts Advantages of carbon fiber parts

Disadvantages of carbon fiber parts

Conclusion

References

Introduction
Carbon fibre, alternatively graphite fibre or CF, is a material consisting of fibres about 5-10 m in diameter and composed mostly of carbon atoms. The carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fibre. The crystal arrangement gives the fibre high strength to volume ratio. Several thousand carbon fibres are bundled together to form a tow, which may be woven into a fabric

Structure of carbon fibre

 The properties of carbon fibres, such as high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion. This makes them very popular in Aerospace, Civil engineering, Military, and Motorsports, along with other competition sports.

Types of carbon fibre sheets used in automobiles

Pre peg carbon fibre sheet These are double sided high gloss carbon fibre sheet designed for applications where the highest strength and best possible surface finish are required (formerly known as robotics grade ). Wet lay carbon fibre sheet Genuine carbon fibre flat sheet, single sided gloss in a range of sizes and thicknesses. Foam-Cored Carbon fibre sheet Vacuum pressed ultra-light single-sided carbon fibre 4mm sandwich panel in a range of large sheet sizes.

Types of carbon fibre components in Automobiles

Carbon fibre parts

Hood Rear spoiler Windshield frame Door panels Engine cover Wheels Body panels Roofs Doors Removable hard top Cockpit Floor A pillar Front crash guard Body and structures Dash panels Propeller shaft Steering wheel

Comparison Of Carbon Fibre parts With Aluminium parts

1.Weight : Carbon fibre parts weigh significantly less than aluminum parts of the same size this means bike/car will weigh less and will take less effort to go faster. 2. Strength: Unlike aluminium, the carbon fibre used to build parts is made of two different materials, carbon and resin, which is why it is called a composite. The long strings of carbon fibre resolutely resist bending and give the material its stiffness, and the resin acts as the glue that holds them together.

3. Flexibility: A carbon fibre part is formed by laying the material in a mould to give it its shape and is cured at high temperatures. Between parts of the same size, aluminium parts are more flexible than carbon fibre parts. We may experience a smoother operation with more shock absorption in aluminium. 4. Braking : Aluminium wheels provide a more powerful braking surface, especially in wet, muddy conditions and on long descents. Some carbon fibre wheels will have aluminium braking surfaces. Since a carbon fibre brake track doesnt dissipate heat as effectively as an aluminium brake track, the heat generated by braking builds up in the wheel and reduces stopping power.

5. Price : Aluminium parts are more affordable than carbon fibre parts. On average, aluminum parts cost about one-third to one-half of what carbon fibre parts cost
6. Shaping: A carbon fibre part is formed by laying the material in a mould to give it its shape and is cured at high temperatures. Shaping the material with a mould, rather than welding tubes together, allows a manufacturer to develop components with clean aerodynamic shapes that are unattainable with metals

 Manufacturing process of carbon fibre parts

The four basic steps in the process of manufacturing a carbon fibre parts are: Mold design. Fabricating the mold. Laying of the Carbon fibre in the mold. Finishing of the part.

 Step1 Mold Design:

The first step in the process is to design a mold that can be used in a repeatable process. In order to design the mold, we must first determine all of the specifications for the part that is to be produced. Using the part specifications, the mold specifications are determined. These specifications must also account for all of the forces needed to successfully press the part. From the mold specifications, a detailed AutoCAD drawing of the mold is created.

 Step 2 Fabricating the Mold After the drawing is completed, a mold can then be fabricated. In order to make the mold, proper materials must be chosen to minimize cost and time. Once these materials have been chosen and obtained, then using the specifications and drawings of the mold, computer code must be written. This code can then be used in the final step, which is machining the mold. Since the machining process could be very expensive, great care must be taken to prepare and test the tools. CNC lathe is the best machine for fabricating the mold.

 Step3 Initial Pressing of the part:

Next, the parts may be cast. To cast the parts, the mold must be properly set up. Then the fibre is to be laid up within the mold. The fibre is then pressed under certain temperature and pressure and is allowed for a certain time to cure. This is the first step in the process of producing a finished working part. The mold must be coated so that the part does not adhere to the mold. The next problem is to lay-up the fibres in such a manner as to minimize the seams and maximize the strength of the fibres.

 Step4 Finishing Process of the part

After the parts have been pressed, the final step can be executed. The final step is finishing and assembling the part and its components. Any excess material that may have flowed out during pressing is trimmed. Then the separate pieces of the parts are assembled so the holes for any necessary bolts or other attachments may be drilled

ADVANTAGES:

. The carbon-fiber composites can reduce a car's weight by up to 60 percent. Reducing a vehicle's weight will increase fuel economy corresponding to the weight being shed. Carbon fiber also benefits race car drivers, as the weight of a vehicle affects the acceleration and overall speed of the car. Carbon fiber parts are 40-60% lighter than the alloy /metal parts. Lowers rotational inertia resulting in quick and responsive steering i.e. less driver fatigue. Carbon fiber used in carbon fiber parts is free from corrosion.

 The low weight but high stiffness of carbon fiber rims produces very light weight rim to wheel ratio, significantly reducing the moment of inertia and unsprung mass. High strength to weight ratio is obtained. Very low co-efficient of thermal expansion. Improved acceleration. Greater fuel economy. Carbon fiber is stiffer than steel, and five times stronger. Carbon fiber can also have a higher energyabsorption rate than steel and increases safety during collision.

DISADVANTAGES: Very expensive When we exceed tensile forces, the strength of the part fails. Recycling process is complicated and tedious. Recycled carbon fibre will be too weak, hence cannot be used in vehicle resulting in more wastage. Dents and cracks cannot be corrected like al parts. Poor resistance to abrasion and shocks. In case of carbon fibre wheels heat dissipation is low compared to al alloy wheel, hence poor braking in carbon fibre wheel. The main disadvantage of this carbon fibre in case of wheel is braking in wet conditions is dangerous. Carbon fiber is an electric conductor

 Conclusion Adaptation of carbon fibre parts in a vehicle is still a budding technology, its used only in high end sports cars and bikes. Installment of carbon fibre parts is a very costly upgrade. Carbon fibre products becomes cheaper in price and the technology can be applied in low end cars and bikes. This will increase the life and durability of the vehicles, hence increasing their efficiency, mileage and other performance characteristics. There is lot of applications of carbon fiber in automobile sector which has resulted in lot of changes. However, if maximum aerodynamic advantage with minimum weight is your goal, then a full carbon fibre products will likely be the better choice

Appendix-1

REFERENCES:
www.wikepedia.org www.carbonfibergear.com www.ezinarticle.com www.ehow.com www.hiperwheel.com www.bikeradar.com Thesis paper of: Department of vehicle engineering Royal Institute of Technology. Stockholm, Sweden. Ford motor research Michigan

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