Formula SAE Hybrid Carbon Fiber Monocoque/ Steel Tube Frame Chassis for the Cal Poly Formula SAE Team Formula Chassis Works Senior Project Matthew Hagan [email protected] John Rappolt [email protected] John Waldrop [email protected] California Polytechnic State University Mechanical Engineering Department Advisor: Dr. Joseph D. Mello v2014-06-01 © 2014 Matthew Hagan, John Rappolt, John Waldrop Formula Chassis Works would like to extend a special thanks to the following people and companies. Without their contributions, this project would not have been possible. Thank you for believing in us! Dr. Joseph D. Mello John Fabijanic Simon Rowe ME Student Fee Allocation Committee AERO Student Fee Committee The Waldrop Family Tabak Law Texas Almet Table of Contents Executive Summary ..................................................................................................................................... 12 1. Introduction ........................................................................................................................................ 13 Problem Statement ................................................................................................................................. 13 Recent Team History ............................................................................................................................... 13 Recent Chassis History ............................................................................................................................ 15 Team Goals.............................................................................................................................................. 16 Project Goals ........................................................................................................................................... 18 Initial Project Direction ........................................................................................................................... 18 2. Project Management .......................................................................................................................... 19 3. Formula SAE Rules .............................................................................................................................. 22 Structures ................................................................................................................................................ 22 Front Protection ...................................................................................................................................... 23 Templates................................................................................................................................................ 24 Harness ................................................................................................................................................... 24 Miscellaneous ......................................................................................................................................... 25 4. Requirements ...................................................................................................................................... 25 Safety ...................................................................................................................................................... 26 Impact ................................................................................................................................................. 27 Intrusion .............................................................................................................................................. 29 Torsional Stiffness ................................................................................................................................... 29 Miscellaneous ......................................................................................................................................... 31 5. Vehicle Design ..................................................................................................................................... 31 6. Full Monocoque Chassis Design and Analysis ..................................................................................... 34 Initial Material Selection ......................................................................................................................... 34 Manufacturing Concept .......................................................................................................................... 35 Geometry and Packaging Development ................................................................................................. 35 Analysis ................................................................................................................................................... 37 Mechanical .......................................................................................................................................... 37 Thermal ............................................................................................................................................... 37 Issues and Switch to Hybrid Chassis ....................................................................................................... 38 7. Hybrid Chassis Design and Analysis .................................................................................................... 41 Loading Sources ...................................................................................................................................... 41 Monocoque ............................................................................................................................................. 42 Geometry ............................................................................................................................................ 42 [3] Laminate Development ....................................................................................................................... 43 Attachments ........................................................................................................................................ 51 Bond .................................................................................................................................................... 53 Frame and Front Hoop ............................................................................................................................ 54 Attachments ........................................................................................................................................ 54 Initial Design ........................................................................................................................................ 55 Torsional Stiffness ............................................................................................................................... 58 Final Construction ............................................................................................................................... 64 Nose Cone/Impact Attenuator ............................................................................................................... 67 8. Laminate Testing and Data Analysis ................................................................................................... 69 Material Properties Testing .................................................................................................................... 69 SAE Laminate Testing .............................................................................................................................. 72 Suspension Attachment/Balsa Core ....................................................................................................... 79 Impact Attenuator Testing ...................................................................................................................... 80 Conclusions ............................................................................................................................................. 83 9. Manufacturing and Vehicle Integration .............................................................................................. 84 Monocoque ............................................................................................................................................. 85 Buck and Mold .................................................................................................................................... 85 Layup and Cure ................................................................................................................................... 88 Bond and Lap Joint .............................................................................................................................. 96 Closeouts ............................................................................................................................................. 99 Inserts ................................................................................................................................................ 100 Fit and Finish ..................................................................................................................................... 101 Frame and Attachments ....................................................................................................................... 103 Jig .....................................................................................................................................................