Download Concepts Generated PowerPoint

P09221: Innovative Composite
Parts for a Formula SAE Racecar
Chassis Concepts: Slides 2-3
Pedal Box Concepts: Slides 4-5
Undertray Concepts: Slides 6-8
Chassis
Roll Hoop Attachment:
1. Bolted
2. Bolted and Bonded
3. Co-cured and bolted
4. Cut out/contour flange
5. Solid planar flange & move fuel cell
Chassis Shape:
1. Curved panels
2. Flat, planar facet
3. Facets with slight curvature/twist
Chassis
Chassis Manufacturing
Wood/MDF/Fiber Glass/Tooling Board Plug
Gel-Coat/Fiberglass Mold
Metal Template Plug
(Photo: Harbor Patterns F-22 Canopy)
Graphite Pre-Preg Mold
(Photo: Harbor Patterns Bell Helicopter Skin Mold)
Pedal Box
Stiffening Scheme:
1. Flat plate w/ core under pedal box
2. Rectangular bonded inserts
3. Ribs bonded in channels
Manufacturing Concepts:
1. Plastic/metal plate with milled channels – Simple mold making process
2. Solid carbon with channels milled in it – No mold required, wastes a lot of
carbon and tooling
3. Pultrusion – Expensive, Increased axial properties, ease of mass production
4. Vacuum Bagging – Cheap, simple, allows any fiber orientation
5. Infusion – Cheap, complicated, allows any fiber orientation
6. Compression Molding – Very simple, poor fiber to resin ratio, allows any fiber
orientation
Pedal Box
Pedal Channel Concepts:
1. Smooth, Large Radii – Ease of Part
Manufacturing, lower peak
normal/in-plane stress
2. Sharp Corners/Small Radii – Ease
of mold manufacturing (no ball-end
mill or surfacing required), lower
out of plane/interlaminar stresses
from radius bending
3. Ribs bonded in channels – less
weight added in stiffeners
4. Stiffening Rectangles Bonded in
Channels – Greater bond surface
area, greater stiffness gains
Undertray
Tunnel Geometry:
1. Large Radii – Ease of
Manufacturing
2. Sharp Corners – Better flow
properties
3. Extend Past Rear Wheels –
Better flow properties
4. Shorter than Rear Wheel
Centerline – Legal, Lighter,
Easier to manufacture
5. Smooth, Elongated Tunnel
Curves – Better flow
properties
6. Flat Plate Facets for Tunnels
– Ease of Mold Making
Undertray
Stiffening:
1. Stiffeners in flow
2. Add no stiffeners
3. Stiffen above tray
Undertray
Jacking Point Concepts:
1. Carbon: Integrated into tray, jack
up car w/ tray
2. Aluminum: Bonded onto tray,
jack up car w/ tray
3. Steel: Cut out undertray, weld
steel to chassis, do not jack up
car w/ tray
Jacking Point Regulations:
1. Must be painted orange
2. Higher than 3” off ground but
below 6.9”
3. Visible from 3 feet away
4. Bottom half of tube must be
exposed
5. Material: steel or aluminum