Design and manufacturing of a Formula Student composite chassis
Mononen, Jussi (2023)
2023
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2023120434148
https://urn.fi/URN:NBN:fi:amk-2023120434148
Tiivistelmä
The purpose of this thesis was to design and manufacture a new chassis for Tampere Formula Student’s formula-style competition vehicle. The development of a new vehicle concept necessitated a corresponding revision of the team’s plans, prompting the need for a fresh chassis design. The opportunity was used to steer away from the traditional space frame opting instead to introduce a new composite chassis concept that would serve as the foundation for future development.
Data from various departments, mainly including suspension and powertrain, was used in the creation of a comprehensive 3D-model of the chassis, accommodating the driver and all the necessary systems. Design decisions for each section of the chassis were made through a process of comparing and evaluating options. The model was developed from the outside in, starting from the outer shell and incorporating material based on the structural properties required for each location. A modular powertrain mounting system was developed utilizing machined aluminium components.
Three distinct panel lay-ups were designed and tested to acquire their properties for use in structural equivalency calculations. A monocoque structure using a foam core sandwich panel configuration was selected. The final structure was constructed using carbon fibre prepreg and PMI foam core material.
Various tooling types and manufacturing methods were compared and assessed. The chosen manufacturing method involves a multi-stage out-of-autoclave cure with carbon fibre prepreg tooling serving as a negative mould. Manufacturing stage was documented in detail highlighting potential issues and considerations. Suggestions are provided for improving the utilization of material data, exploring different core materials and optimizing the roll hoops and front bulkhead area of the chassis.
Data from various departments, mainly including suspension and powertrain, was used in the creation of a comprehensive 3D-model of the chassis, accommodating the driver and all the necessary systems. Design decisions for each section of the chassis were made through a process of comparing and evaluating options. The model was developed from the outside in, starting from the outer shell and incorporating material based on the structural properties required for each location. A modular powertrain mounting system was developed utilizing machined aluminium components.
Three distinct panel lay-ups were designed and tested to acquire their properties for use in structural equivalency calculations. A monocoque structure using a foam core sandwich panel configuration was selected. The final structure was constructed using carbon fibre prepreg and PMI foam core material.
Various tooling types and manufacturing methods were compared and assessed. The chosen manufacturing method involves a multi-stage out-of-autoclave cure with carbon fibre prepreg tooling serving as a negative mould. Manufacturing stage was documented in detail highlighting potential issues and considerations. Suggestions are provided for improving the utilization of material data, exploring different core materials and optimizing the roll hoops and front bulkhead area of the chassis.