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Design of a Carbon Fiber Composite Monocoque Chassis for a Formula Style Vehicle

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Design of a Carbon Fiber Composite Monocoque Chassis for a Formula Style Vehicle Western Michigan University ScholarWorks at WMU Honors Theses Lee Honors College 4-14-2020 Design of a Carbon Fiber Composite Monocoque Chassis for a Formula Style Vehicle Mitchell Hiller Western Michigan University, [email protected] Follow this and additional works at: https://scholarworks.wmich.edu/honors_theses Part of the Mechanical Engineering Commons Recommended Citation Hiller, Mitchell, "Design of a Carbon Fiber Composite Monocoque Chassis for a Formula Style Vehicle" (2020). Honors Theses. 3262. https://scholarworks.wmich.edu/honors_theses/3262 This Honors Thesis-Open Access is brought to you for free and open access by the Lee Honors College at ScholarWorks at WMU. It has been accepted for inclusion in Honors Theses by an authorized administrator of ScholarWorks at WMU. For more information, please contact [email protected]. Design of a Carbon Fiber Composite Monocoque Chassis for a Formula-Style Vehicle ME 4800 – Senior Design Project Project Team 8: Alex Carline, Mitchell Hiller, Riley Masters Faculty Advisor: Dr. Kujawski Spring 2020 1 Disclaimer WESTERN MICHIGAN UNIVERSITY MAKES NO REPRESENTATION THAT THE MATERIAL PRESENTED AS A RESULT OF THIS SENIOR ENGINEERING DESIGN PROJECT IS ERROR-FREE OR COMPLETE IN ALL RESPECTS. PERSONS OR ORGANIZATIONS WHO CHOOSE TO USE THE MATERIAL DO SO AT OWN RISK. 2 Abstract Western Michigan University’s Formula SAE team, Bronco Racing, designs and manufactures a formula-style vehicle to compete annually at an international collegiate design and racing competition. In order to remain competitive, Bronco Racing required a lighter chassis for the 2021 vehicle. To achieve this, the full 2020 carbon fiber monocoque chassis system was redesigned to be lightweight while considering packaging constraints, the Formula SAE rules, and design parameters set by Bronco Racing. The monocoque geometry was modeled using SolidWorks and the carbon composite was simulated, tested, and verified using ANSYS and quasi-static load frame testing. The newly designed 2021 monocoque chassis when compared to the 2020 decreases weight by 8.24 kg and cuts cost by $3,442.57. Also, a comprehensive manufacturing plan was then produced, allowing Bronco Racing to manufacture the monocoque to design specifications. 3 Table of Contents Abstract ........................................................................................................................................... 3 List of Tables ................................................................................................................................ 10 List of Figures ............................................................................................................................... 11 Nomenclature ................................................................................................................................ 20 1 Introduction ........................................................................................................................... 22 1.1 Background ................................................................................................................... 22 2 BR20 Drawbacks ................................................................................................................... 23 2.1 Laminate Design ........................................................................................................... 23 2.2 Packaging Considerations ............................................................................................. 27 2.3 Manufacturing Quality .................................................................................................. 29 2.3.1 Tooling Board ........................................................................................................... 29 2.3.2 Male Molds ............................................................................................................... 29 2.3.3 Fiberglass Molds ....................................................................................................... 30 2.3.4 Monocoque Manufacture .......................................................................................... 32 2.3.5 Trimming and Lap Joint ............................................................................................ 33 3 BR21 Design ......................................................................................................................... 34 3.1 Initial Concepts ............................................................................................................. 34 3.2 Geometrical Constraints ............................................................................................... 35 3.2.1 Suspension Constraints ............................................................................................. 35 3.2.2 Powertrain Constraints .............................................................................................. 38 3.2.2.1 Powertrain and Drivetrain Removal ................................................................. 38 3.2.2.2 Cooling .............................................................................................................. 39 3.2.2.3 Packaging Changes ........................................................................................... 40 3.2.3 Driver Controls Constraints ...................................................................................... 41 3.2.3.1 Steering Wheel Position .................................................................................... 41 3.2.3.2 Cockpit Template .............................................................................................. 42 3.2.4 Center of Gravity Changes ........................................................................................ 43 3.3 Material Selection ......................................................................................................... 46 3.3.1 Carbon Fiber ............................................................................................................. 46 3.3.2 Core ........................................................................................................................... 48 3.3.3 Composite Panel Potted Inserts................................................................................. 48 3.4 Laminate Analysis Setup .............................................................................................. 50 4 3.4.1 Laminate Region Breakdown.................................................................................... 52 3.4.2 Mesh Creation ........................................................................................................... 55 3.4.3 Load Cases ................................................................................................................ 57 3.4.3.1 Front Suspension Load Case............................................................................. 58 3.4.3.2 Rear Suspension Load Case .............................................................................. 59 3.4.3.3 Rollover Load Case .......................................................................................... 61 3.4.3.4 Front Impact Load Case .................................................................................... 62 3.4.4 Analysis method ........................................................................................................ 66 3.5 Analysis by Region ....................................................................................................... 66 3.5.1 Front Bulkhead (FBH) .............................................................................................. 66 3.5.1.1 Rules Equivalence ............................................................................................. 67 3.5.1.2 Front Impact Simulation ................................................................................... 68 3.5.2 Front Bulkhead Support (FBHS) .............................................................................. 69 3.5.2.1 Rules Equivalence ............................................................................................. 70 3.5.2.2 Suspension Hardpoints ..................................................................................... 72 3.5.3 Front Roll Hoop ........................................................................................................ 74 3.5.3.1 Rules Equivalence ............................................................................................. 75 3.5.3.2 Simulation with Steering Loads ........................................................................ 76 3.5.4 Horizontal Side Impact Structure (HSIS) ................................................................. 78 3.5.4.1 Rules Equivalence ............................................................................................. 79 3.5.4.2 Harness Mounting ............................................................................................. 80 3.5.5 Main Roll Structure ................................................................................................... 82 3.5.5.1 Main Roll Hoop ................................................................................................ 82 3.5.5.2 Shoulder Harness Bar ....................................................................................... 84 3.5.5.3 Main Hoop Bracing .......................................................................................... 85 3.5.6 Main Hoop Bracing Support (MHBS) .....................................................................
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