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Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

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Języki publikacji
EN
Abstrakty
EN
This case study describes a manufacturing process of composite chassis also known as monocoque. The structure is made using carbon fibre reinforced polymers (CFRP) which are manufactured in out-of-autoclave (OOA) process from pre-impregnated carbon fabrics and aluminium alloy honeycomb core. Since the material cost is high the aim of the project was to reduce the cost of manufacturing process i.e. cost of models and moulds. Therefore, instead of high-temp models and moulds a cheaper alternative was used. It consisted of Styrofoam models made using polyurethane (PU) paste and moulds made from CFRP using wet layup process which were cured at room temperature. Such moulds had to be adapted to withstand high temperatures during pre-preg cure. This was done with gradual heat annealing process which increased the maximum service temperature from 45C to 90C. This was enough for the low-temp cure of pre-preg material, but it might be possible to increase the temperature even further. As a result, the cost of manufacturing process had been reduced by 50%.
Twórcy
  • Institute of Aeronautics and Applied Mechanics, Warsaw University of Technology, ul. Nowowiejska 24, 00-665 Warsaw, Poland
  • Institute of Aeronautics and Applied Mechanics, Warsaw University of Technology, ul. Nowowiejska 24, 00-665 Warsaw, Poland
autor
  • Institute of Aeronautics and Applied Mechanics, Warsaw University of Technology, ul. Nowowiejska 24, 00-665 Warsaw, Poland
  • Institute of Aeronautics and Applied Mechanics, Warsaw University of Technology, ul. Nowowiejska 24, 00-665 Warsaw, Poland
Bibliografia
  • 1. Li Z., Ma J. Experimental Study on Mechanical Properties of the Sandwich Composite Structure Reinforced by Basalt Fiber and Nomex Honeycomb. Materials. 2020; 13: 1870.
  • 2. Yu H., Zhao H., Shi F. Bending Performance and Reinforcement of Rocker Panel Components with Unidirectional Carbon Fiber Composite. Materials. 2019; 12: 3164. DOI: 10.3390/ma12193164.
  • 3. Akay M., Hannah R. A comparison of honeycombcore and foam core CarbonFibre/Epoxy sandwich Panels. Composites. 1990; 21: 325–331.
  • 4. Olsen E.V., Lemu H.G. Mechanical Testing of Composite Materials for Monocoque Design in Formula Student Car. International Journal of Mechanical and Mechatronics Engineering. 2016.
  • 5. Yaqoob M. Fabrication and structural equivalency analysis of cfrp nomex core sandwiched panels for fsae race car. Unsw Canberra Adfa J. Undergrad. Eng. Res. 2017; 12. https://ojs.unsw.adfa.edu.au/index.php/juer/article/view/1084 .
  • 6. Xiao Y., Hu, Y., Zhang J., Song C., Huang X., Yu J., Liu Z. The Bending Responses of Sandwich Panels with Aluminium Honeycomb Core and CFRP Skins Used in Electric Vehicle Body. Adv. Mater. Sci. Eng. 2018; 2018: 1–11. DOI: 10.1155/2018/5750607
  • 7. Shi S., Sun Z., Hu X., Chen H. Flexural strength and energy absorption of carbon-fiber–aluminum-honeycomb composite sandwich reinforced by aluminum grid. Thin-Walled Struct. 2014; 84: 416–422. DOI: 10.1016/j.tws.2014.07.015
  • 8. Zhang Y., Zong Z., Liu Q., Ma J., Wu Y., Li Q. Static and dynamic crushing responses of CFRP sandwich panels filled with different reinforced materials. Mater. Des. 2017; 117: 396–408.
  • 9. Sun Z., Hu X., Sun S., Chen H. Energy-absorption enhancement in carbon-fiber aluminum-foam sandwich structures from short aramid-fiber interfacial reinforcement. Compos. Sci. Technol. 2013; 77: 14–21, DOI: 10.1016/j.compscitech.2013.01.016
  • 10. Jakubiak S., Ćwikła F., Rządkowski W. Mechanical Properties Investigation of Composite Sandwich Panel and Validation of FEM Analysis, Materials Research Proceedings. 2019; 12: 1–8.
  • 11. Mogilski M., Jabłoński M., Deroszewska M., Saraczyn R., Tracz J., Kowalik M., Rządkowski W. Investigation of Energy Absorbed by Composite Panels with Honeycomb Aluminum Alloy Core. Materials. 2020; 13: 5807. https://doi.org/10.3390/ma13245807
  • 12. Denny J., Veale K., Adali S., Leverone F. Conceptual design and numerical validation of a composite monocoque solar passenger vehicle chassis, Engineering Science and Technology, an International Journal. 2018; 21(5): 1067–1077.
  • 13. Wu J., Badu O.A., Tai Y., George A.R. Design, analysis, and simulation of an automotive carbon fiber monocoque chassis. Cornell University, Jan 2014 - SAE International.
  • 14. Eurenius C.A., Danielsson N., Khokar A., Krane E., Olofsson M., Wass J. 2013. Analysis of Composite Chassis.
  • 15. Kharabe V., Jere R., Sabu P., Patil P., Thakare N. Novel way of manufacturing a carbon fiber monocoque chassis. International Research Journal of Engineering and Technology. 2019; 6(5).
  • 16. Messana A., Sisca L., Ferraris A., Airale A.G., de Carvalho Pinheiro H., Sanfilippo P., Carello M. From Design to Manufacture of a Carbon Fiber Monocoque for a Three-Wheeler Vehicle Prototype. Materials. 2019; 12: 332.
  • 17. Hamilton L., Joyce P., Forero C., McDonald M. 2013. Production of a Composite Monocoque Frame for a Formula SAE Racecar. DOI: 10.4271/2013-01-1173.
  • 18. Buntine J.E. Design of a carbon fibre monocoque for a Formula SAE racing car. UNSW Canberra at ADFA.
  • 19. Hiller M. Design of a Carbon Fiber Composite Monocoque Chassis for a Formula Style Vehicle. Lee Honors College, 2020.
  • 20. Shi L., Rice K. Carbon Fibre Composite Monocoque Chassis for a Formula Student Race Car. Monash Motorsport. 2019.
  • 21. XC110 210g 2x2 Twill 3k Prepreg Carbon Fibre manufactured by Easy composites Ltd, Stoke-on-Trent, England. 2020. https://www.easycomposites.co.uk/xc110-210g-22-twill-3k-prepreg-carbon-fibre (accessed on December 2020).
  • 22. Technical Datsheet of 3.2mm (1/8”) Cell Aluminium Honeycomb. manufactured by Easy composites Ltd, Stoke-on-Trent, England. 2020. https://www.easycomposites.co.uk/3mm-aluminium-honeycomb (accessed on December 2020).
  • 23. XA120 150g Prepreg Adhesive Film manufactured by Easy composites Ltd, Stoke-on-Trent, England. 2020, available online: https://www.easycomposites.co.uk/xa120-prepreg-adhesive-film (accessed on December 2020).
  • 24. Easy Composites, “How to Make a Prepreg Carbon Fibre Mould (Using XPREG® Tooling Prepreg)”. https://www.youtube.com/watch?v=k4GdAuNji5g.
  • 25. Biresin m72. https://www.tr-solution.pl/uploads/pdf/Biresin%20M72.pdf.
  • 26. Medacoat paste.
  • 27. Laminating resin LH 385, acquired from https://www.havel-composites.com/en/products/epoxy-resin-lh-385
  • 28. Hardener H 285 MGS, acquired from https://www.havel-composites.com/en/products/hardener-h-285-havel-replacement-of-285-mgs-pot-life-50-min-3646-8192.
Uwagi
Opracowanie rekordu ze środków MEiN, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2022-2023).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-a151cb71-b496-492b-98a6-6c896b5a6b5b
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