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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