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Design of a Carbon Fibre Passenger Car Rim

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Design of a Carbon Fibre Passenger Car Rim DESIGN OF A CARBON FIBRE PASSENGER CAR RIM Lehoelere Frederick Maserumule A research report submitted to the Faculty of Engineering and Built Environment of the University of the Witwatersrand in partial fulfilment of the requirements for the degree of Master of Science in Engineering. Johannesburg 2015 Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Declaration I Lehoelere Frederick Maserumule hereby declare that this research report is my own unaided work. It is being submitted to the Degree of a Masters in Science in Engineering to the University of the Witwatersrand, Johannesburg. It has not been submitted before for any degree or examination to any other University. …………………………………………………………………………… L.F Maserumule 0505585E ……….. day of …………….., …………… ii Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Dedication In memory of my late aunt Masemola Granny iii Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Acknowledgements I would like to acknowledge Dr Frank Kienhofer (my supervisor) for his assistance in obtaining the strain gauge experimental test results of the 1098 Ducati Rim. His supervisory role provided the necessary assistance and guidance in the key aspects of this research report. The guidance of Craig Goodrum was also invaluable in understanding composite theory, and the manufacturing process of the rim at BlackStone Tek. I would like to thank Makgomo Maserumule, Frank Maserumule, Tseke Maserumule, Mamagane Maserumule and Ayanda Mkhasibe for the emotional support during the research process. iv Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Abstract The wheel is an important component for all land transport vehicles and the following research report investigates the feasibility of a passenger car wheel manufactured from carbon fibre. Previous research, evaluated a strain gauged BlackStone Tek motorcycle Ducati rim loaded to 700 Nm on a dynamic cornering test machine. In the current study, these experimental results were used to validate an FEA model of the BlackStone Tek Ducati rim. The validated FEA was used to investigate the feasibility of using carbon fibre to manufacture a passenger car rim. The FEA model did not include the aluminium hub, and the analysis was therefore considered valid for the spokes and rim only. The FEA strains of the Ducati rim spokes were within an acceptable 25% correlation range with the experimental results. The FEA strains were generally higher than the experimental results. Having validated the FEA model, a carbon fibre passenger car rim, was analysed at a bending moment of 2000 Nm. The inverse of the factor of safety from the spoke to the rim section was below 1. This indicates that the newly designed rim should pass the dynamic cornering test, a vital standard proving that the rim is structurally durable to function on a small to medium sized passenger car. In comparison to aluminium rims of the equivalent size, a weight saving of 62.2% can be expected from a carbon fibre passenger car rim. v Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Table of Contents Declaration .......................................................................................................................... ii Dedication .......................................................................................................................... iii Acknowledgements ........................................................................................................... iv Abstract ............................................................................................................................... v Table of Contents ............................................................................................................... vi List of Figures .................................................................................................................. viii List of Tables ...................................................................................................................... xi List of Symbols ................................................................................................................. xii Chapter 1: Introduction ...................................................................................................... 1 1.1 Background ........................................................................................................................... 1 1.2 BlackStone Tek Ducati Rim ................................................................................................ 3 1.3 Wheel Test Methods ............................................................................................................ 4 1.4 Problem Description ............................................................................................................. 6 1.5 The Proposal ......................................................................................................................... 7 Chapter 2: General Theory ................................................................................................. 8 2.1 Design Standards for Wheels ............................................................................................. 9 2.2 Experimental Analysis of the Ducati Rim ........................................................................ 12 2.2.1 Stress strain relationship of a lamina ...................................................................... 12 2.2.2 Principles of strain gauging ....................................................................................... 14 Chapter 3: Literature Review ............................................................................................ 16 3.1 Experimental Analysis ....................................................................................................... 16 3.2 Numerical Analysis ............................................................................................................. 19 3.3 Previous Work on Composites ......................................................................................... 21 Chapter 4: Objectives ....................................................................................................... 22 4.1 Research Scope ................................................................................................................. 22 4.2 Research Outline ................................................................................................................ 23 vi Design of a Carbon Fibre Passenger Car Rim ___________________________________________________________________ Chapter 5: Experimental Analysis: 1098 Ducati Rim ...................................................... 24 Chapter 6: FEA: 1098 Ducati Rim ..................................................................................... 27 6.1 Methodology ........................................................................................................................ 27 6.1.1 Model preparation ...................................................................................................... 27 6.1.2 Project schematic ....................................................................................................... 29 6.1.3 Material design ........................................................................................................... 30 6.1.4 Meshing ....................................................................................................................... 39 6.1.5 Load cases .................................................................................................................. 41 6.2 Result Evaluation: Current 1098 Ducati Rim ............................................................... 43 6.2.1 Strains .......................................................................................................................... 43 6.2.2 Maximum strain: failure criterion .............................................................................. 48 Chapter 7: FEA – Passenger Car Rim .............................................................................. 56 7.1 Ducati Rim Exposed to Passenger Vehicle Loads ........................................................ 58 7.1.1 Strains .................................................................................................................................. 58 7.1.2 Maximum strain failure criterion ....................................................................................... 61 7.2 Model Preparation .............................................................................................................. 64 7.2.1 Segmentation .............................................................................................................. 65 7.2.2 Stacking sequence ..................................................................................................... 65 7.2.3 Meshing ....................................................................................................................... 71 7.3 Result Evaluation: Passenger Vehicle Rim .................................................................. 72 7.3.1 Strains .........................................................................................................................
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