Creating a Future for Engineers

Formula Student Germany

FSAE-CFRP monocoque
Creating a Future for Engineers
Contents
Motivation
Concept
Dimensioning
Design
Cuts
Manufacturing

Creating a Future for Engineers
+ mass-specific mechanical properties
+ safety
+ lightweight design possibilities
+ integration of functions
+ (new challenge)
Motivation
- time and cost (depends)
- design complexity
- maintenance and repair
Why a Monocoque?
Has to be answered during design event!
Creating a Future for Engineers
axle to axle front-only
more interaction
no additional load transmissions
one-piece multi-part
manufacturability
no joint
push- pullrod
considerable influence on MC-design
Concepts Basic Options
manufacturing method
wide influence on MC-design
influence on cost
joint integrated
manufacturability
no joint
ergonomy und package
tool mock-up
shouldnt change too often
Creating a Future for Engineers
Concepts Geometry Variation
simplified FE-model qualitative analysis
of concepts
initially: isotropic material
presumed weaknesses:
upper wishbones
cockpit
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Influence on Torsional Stiffness
0.00
1.00
2.00
3.00
4.00
massenspezifische Torsionssteifigkeit (normiert)
Geschlossen, mit Spant
Offen, mit Spant
Unverstrkt, mit Spant
Geschlossen, ohne Spant
Offen, ohne
Creating a Future for Engineers
300 mm
F = 177 kN
Preliminary Design: Frontal Crash
Creating a Future for Engineers
no. material E
||
E
^
G
^||
n
^||
r
Corres
ponding j
1 E-Glas / EP 44480 13219 5562 0,25 2 0,6
2 HTA/MTM49-3 125650 9800 4580 0,335 1,55 0,6
3 T700S/MTM49-3 125300 9105 3830 0,33 1,55 0,6
no. material R
||
t
R
||
c
R
^
t
R
^
c
R
^||

Corres
ponding j
1 E-Glas / EP 1100 1000 54 150 75 0,6
2 HTA/MTM49-3 1810 1455 35,3 232 89,3 0,6
3 T700S/MTM49-3 2662 1386 28,3 180,2 56,8 0,6
loads
n
x
[N/mm] -147,5
laminate lay-up
lamina t
k
[mm] a j material
1
0,116 0 0,49 8
2
0,116 90 0,49 8
3
0,116 45 0,49 8
4
0,116 -45 0,49 8
5
0,462 0 0,49 8
6
0,116 -45 0,49 8
7
0,116 45 0,49 8
8
0,116 90 0,49 8
9
0,116 0 0,49 8
lamina angle [a] e
1
[%] e
2
[%] g
21
[%] s
1
[N/mm
2
] s
2
[N/mm
2
] t
21
[N/mm
2
] f
E,FF
f
E,IFF

Fracture
mode
Fracture
angle
weakening
1 0,00 -0,17 0,05 0 -179,6 0,5 0 0,15 0,01 A 0 3
2 90,00 0,05 -0,17 0 51,6 -12,9 0 0,03 0,06 C 51,22 2
3 45,07 -0,06 -0,06 0,23 -63,8 -6,2 8,6 0,05 0,08 B 0 2
4 -45,07 -0,06 -0,06 -0,23 -63,8 -6,2 -8,6 0,05 0,08 B 0 2
5 0,00 -0,17 0,05 0 -179,6 0,5 0 0,15 0,01 A 0 3
6 -45,07 -0,06 -0,06 -0,23 -63,7 -6,2 -8,6 0,05 0,08 B 0 2
7 45,07 -0,06 -0,06 0,23 -63,7 -6,2 8,6 0,05 0,08 B 0 2
8 90,00 0,05 -0,17 0 51,6 -12,9 0 0,03 0,06 C 51,2 2
9 0,00 -0,17 0,05 0 -179,2 0,5 0 0,15 0,01 A 0 3
http://www.klub.tu-darmstadt.de/forschung/download.php
reserve factor
laminate fracture
6,6
reserve factor first
inter-fibre fracture
6,6
CLT
Creating a Future for Engineers
FE-Model
anisotropic material
align element coordinate system!
shell elements
Ansys: SHELL99, SHELL91
Input of single plies enables CLT
and Puck to be used in Ansys
reasonable results without tests?
Creating a Future for Engineers
1. Load Transmission
2. Bonded Joint
3. Cockpit Reinforcement
Design in Detail
1
2
3
Creating a Future for Engineers
Load Transmission
critical
safety seat belt
suspension
complex detailed calculations
tests are more reasonable
integration of functions
roll hoops
Creating a Future for Engineers
Bonded Joint
Creating a Future for Engineers
Cockpit Reinforcement
Creating a Future for Engineers
Machine-Cut Plies
(Vistagy Fibersim, CATIA Composite Design, NX Laminate Composites)
+ less wasted material
+ faster manufacturing
+ higher quality
each cut CAD surface model
3d surface 2d contour *.dxf
N
X
4

splines lines and circular arcs
reduce number of segments
nesting
A
u
t
o
c
a
d

Creating a Future for Engineers
Ply Book
ply book pages for overview and for each cut
in sequence of actual manufacturing steps
if necessary: exact position and alignment
Creating a Future for Engineers
Manufacturing
Epoxy blocks cut
and bonded
5 axis mill

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fine-grained abrasive paper
mould release agent
alignment pins

CFK tooling prepregs
(2x200gr | 3x650gr | 1x200gr)s
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autoclave curing of negative moulds defrosting of prepregs
CNC cut plies
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labeling and arranging first face
positioning via pins
Creating a Future for Engineers
inserts are also nested
CFK panel jet cutting
honeycomb core machine cut
insert positioning via pins
Creating a Future for Engineers
vacuum parts to be cured in autoclave
2 or 3 shots

Creating a Future for Engineers
removing alignment pins
demoulding
bonding
tension belts

Creating a Future for Engineers
Tips for a Start
Concept
examine concepts and solutions of
other teams
define manufacturing method early
(depends on your options and those
provided by partners)
Design
define package early
lightweight construction!
symmetrical ply layout
complete CAD model
avoid unnecessary joints
Material
high-tension fibres arent beneficial
for axial compression
high modulus fibres: brittle, low
ultimate elongation!
fabric: fine, compact, not wavy
twill or sateen (e. g. 3k-yarn: 200g/m
for instance)
local UD reinforcements (e. g. for
distinct, not varying state of stress)
core: e. g. fine aluminum
honeycombs of low density
Creating a Future for Engineers

05. 09. August 2009
See you at Hockenheim