Mechanical Testing of Composite Materials for Monocoque Design in Formula Student Car
Inspired by the Formula-1 competition, IMechE
(Institute of Mechanical Engineers) and Formula SAE (Society of
Mechanical Engineers) organize annual competitions for University
and College students worldwide to compete with a single-seat racecar
they have designed and built. Design of the chassis or the frame is a
key component of the competition because the weight and stiffness
properties are directly related with the performance of the car and the
safety of the driver. In addition, a reduced weight of the chassis has
direct influence on the design of other components in the car. Among
others, it improves the power to weight ratio and the aerodynamic
performance. As the power output of the engine or the battery
installed in the car is limited to 80 kW, increasing the power to
weight ratio demands reduction of the weight of the chassis, which
represents the major part of the weight of the car. In order to reduce
the weight of the car, ION Racing team from University of
Stavanger, Norway, opted for a monocoque design. To ensure
fulfilment of the competition requirements of the chassis, the
monocoque design should provide sufficient torsional stiffness and
absorb the impact energy in case of possible collision. The study reported in this article is based on the requirements for
Formula Student competition. As part of this study, diverse
mechanical tests were conducted to determine the mechanical
properties and performances of the monocoque design. Upon a
comprehensive theoretical study of the mechanical properties of
sandwich composite materials and the requirements of monocoque
design in the competition rules, diverse tests were conducted
including 3-point bending test, perimeter shear test and test for
absorbed energy. The test panels were homemade and prepared with
equivalent size of the side impact zone of the monocoque, i.e. 275
mm x 500 mm, so that the obtained results from the tests can be
representative. Different layups of the test panels with identical core
material and the same number of layers of carbon fibre were tested
and compared. Influence of the core material thickness was also
studied. Furthermore, analytical calculations and numerical analysis
were conducted to check compliance to the stated rules for Structural
Equivalency with steel grade SAE/AISI 1010. The test results were
also compared with calculated results with respect to bending and
torsional stiffness, energy absorption, buckling, etc. The obtained results demonstrate that the material composition
and strength of the composite material selected for the monocoque
design has equivalent structural properties as a welded frame and thus
comply with the competition requirements. The developed analytical
calculation algorithms and relations will be useful for future
monocoque designs with different lay-ups and compositions.
[1] M. H. Mat, A. R. Ab. Ghani, “Design and analysis of ‘Eco’ car chassis”,
Engineering Procedia, vol. 41, pp. 1756 – 1760, 2012.
[2] A. Airale, M. Carello, A. Scattina, “Carbon fiber monocoque for a
hydrogen prototype for low consumption challenge”, Mat.-wiss.
u.Werkstofftech. vol. 42, no. 5, 2011.
[3] 2015 Formula SAE® Rules – 09/17/2014 Revision, FSAE-online,
http://www.fsaeonline.com/
[4] R.F. Gibson, “A review of recent research on mechanics of
multifunctional composite materials and structures”, Compos. Struct.
vol. 92, pp. 2793–2810, 2010.
[5] G.F. Smith, “Design and production of composites in the automotive
industries” Compos. Manuf. vol. 1, no. 2, pp. 112–116, 1990.
[6] M. Pinfold, G. Calvert, “Experimental analysis of a composite
automotive suspension arm”, Compos. vol. 25, no. 1, pp. 56–93, 1994.
[7] W.T. Freeman, “The use of composites in aircraft primary structure”,
Compos. Eng., vol. 3, no. 7-8, pp. 767–775, 1993.
[8] C. Soutis, “Fibre reinforced composites in aircraft construction”,
Compos. Struct., vol. 76, pp. 34–46, 2006.
[9] Veers, et al. “Trends in the design, manufacture and evaluation of wind
turbine blades”, Wind Energ., vol. 6, pp. 245–259, 2003.
[10] G. Marsh, “Composites help improve wind turbine breed”, Reinf. Plast.,
vol. 49, no. 4, pp. 18-22, 2005.
[11] J.Y. Cognarda, P. Daviesb, L. Sohierc, R. Créac’hcadeca, “A study of
the non-linear behaviour of adhesively-bonded composite assemblies”,
Compos. Struct., vol. 76, pp. 34–46, 2006.
[12] S. Selvaraju, S. Ilaiyavel, “Application of composites in marine
industry”, J. Eng. Res.Stud., vol. 2, no. 2, pp. 89 – 91, 2011.
[13] P.F. Liu, J.Y. Zheng, “Review on methodologies of progressive failure
analysis of composite laminates, in Continuum mechanics, eds. A.
Koppel and J. Oja, New York: Nova Science Publishers; 2009.
[14] Z. Li, B. Sun, B. Gu, “FEM simulation of 3D angle-interlocked woven
composite under ballistic impact from unit cell approach” Compos.
Mater. Sci, vol. 49, pp. 171–83, 2010.
[15] Y.X. Zhang, C.H. Yang, “Recent developments in finite element
analysis for laminated composite plates”, Compos. Struct. vol. 88, pp.
147–157, 2009.
[16] P.F. Liu , J.Y. Zheng, “Recent developments on damage modeling and
finite element analysis for composite laminates: A review”, Mater. Des.
31, pp. 3825–3834, 2010.
[17] C.R. Dandekar, Y.C. Shin, “Modeling of machining of composite
materials: A review”, Int. J. Mach. Tools Manuf., vol. 57, pp. 102–121,
2012.
[18] H.C. Davies, M. Bryant, M. Hope, C. Meiller, “Design, development,
and manufacture of an aluminium honeycomb sandwich panel
monocoque chassis for Formula Student competition”, Proc. of the
Institution of Mechanical Engineers, Part D: J. Automobile Eng., vol.
226, no. 3, pp. 325-337, March 2012.
[19] E. Brinkworth, D. Jaggard, M. Royds-Jones, et al., "Application of FEA
Techniques to a Hybrid Racing Car Chassis Design," SAE Technical
Paper 2000-01-3538, 2000.
[20] H. Altenbach, “Theories for laminated and sandwich plates, a review”,
Mech Compos Mater. vol. 34, no. 3, pp. 243–152, 1998.
[21] J.N. Reddy, D.H. Robbins Jr., “Theories and computational models for
composite laminates”, Appl. Mech. Rev., vol. 47, pp. 147–69, 1994.
[1] M. H. Mat, A. R. Ab. Ghani, “Design and analysis of ‘Eco’ car chassis”,
Engineering Procedia, vol. 41, pp. 1756 – 1760, 2012.
[2] A. Airale, M. Carello, A. Scattina, “Carbon fiber monocoque for a
hydrogen prototype for low consumption challenge”, Mat.-wiss.
u.Werkstofftech. vol. 42, no. 5, 2011.
[3] 2015 Formula SAE® Rules – 09/17/2014 Revision, FSAE-online,
http://www.fsaeonline.com/
[4] R.F. Gibson, “A review of recent research on mechanics of
multifunctional composite materials and structures”, Compos. Struct.
vol. 92, pp. 2793–2810, 2010.
[5] G.F. Smith, “Design and production of composites in the automotive
industries” Compos. Manuf. vol. 1, no. 2, pp. 112–116, 1990.
[6] M. Pinfold, G. Calvert, “Experimental analysis of a composite
automotive suspension arm”, Compos. vol. 25, no. 1, pp. 56–93, 1994.
[7] W.T. Freeman, “The use of composites in aircraft primary structure”,
Compos. Eng., vol. 3, no. 7-8, pp. 767–775, 1993.
[8] C. Soutis, “Fibre reinforced composites in aircraft construction”,
Compos. Struct., vol. 76, pp. 34–46, 2006.
[9] Veers, et al. “Trends in the design, manufacture and evaluation of wind
turbine blades”, Wind Energ., vol. 6, pp. 245–259, 2003.
[10] G. Marsh, “Composites help improve wind turbine breed”, Reinf. Plast.,
vol. 49, no. 4, pp. 18-22, 2005.
[11] J.Y. Cognarda, P. Daviesb, L. Sohierc, R. Créac’hcadeca, “A study of
the non-linear behaviour of adhesively-bonded composite assemblies”,
Compos. Struct., vol. 76, pp. 34–46, 2006.
[12] S. Selvaraju, S. Ilaiyavel, “Application of composites in marine
industry”, J. Eng. Res.Stud., vol. 2, no. 2, pp. 89 – 91, 2011.
[13] P.F. Liu, J.Y. Zheng, “Review on methodologies of progressive failure
analysis of composite laminates, in Continuum mechanics, eds. A.
Koppel and J. Oja, New York: Nova Science Publishers; 2009.
[14] Z. Li, B. Sun, B. Gu, “FEM simulation of 3D angle-interlocked woven
composite under ballistic impact from unit cell approach” Compos.
Mater. Sci, vol. 49, pp. 171–83, 2010.
[15] Y.X. Zhang, C.H. Yang, “Recent developments in finite element
analysis for laminated composite plates”, Compos. Struct. vol. 88, pp.
147–157, 2009.
[16] P.F. Liu , J.Y. Zheng, “Recent developments on damage modeling and
finite element analysis for composite laminates: A review”, Mater. Des.
31, pp. 3825–3834, 2010.
[17] C.R. Dandekar, Y.C. Shin, “Modeling of machining of composite
materials: A review”, Int. J. Mach. Tools Manuf., vol. 57, pp. 102–121,
2012.
[18] H.C. Davies, M. Bryant, M. Hope, C. Meiller, “Design, development,
and manufacture of an aluminium honeycomb sandwich panel
monocoque chassis for Formula Student competition”, Proc. of the
Institution of Mechanical Engineers, Part D: J. Automobile Eng., vol.
226, no. 3, pp. 325-337, March 2012.
[19] E. Brinkworth, D. Jaggard, M. Royds-Jones, et al., "Application of FEA
Techniques to a Hybrid Racing Car Chassis Design," SAE Technical
Paper 2000-01-3538, 2000.
[20] H. Altenbach, “Theories for laminated and sandwich plates, a review”,
Mech Compos Mater. vol. 34, no. 3, pp. 243–152, 1998.
[21] J.N. Reddy, D.H. Robbins Jr., “Theories and computational models for
composite laminates”, Appl. Mech. Rev., vol. 47, pp. 147–69, 1994.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:71624", author = "Erik Vassøy Olsen and Hirpa G. Lemu", title = "Mechanical Testing of Composite Materials for Monocoque Design in Formula Student Car", abstract = "Inspired by the Formula-1 competition, IMechE
(Institute of Mechanical Engineers) and Formula SAE (Society of
Mechanical Engineers) organize annual competitions for University
and College students worldwide to compete with a single-seat racecar
they have designed and built. Design of the chassis or the frame is a
key component of the competition because the weight and stiffness
properties are directly related with the performance of the car and the
safety of the driver. In addition, a reduced weight of the chassis has
direct influence on the design of other components in the car. Among
others, it improves the power to weight ratio and the aerodynamic
performance. As the power output of the engine or the battery
installed in the car is limited to 80 kW, increasing the power to
weight ratio demands reduction of the weight of the chassis, which
represents the major part of the weight of the car. In order to reduce
the weight of the car, ION Racing team from University of
Stavanger, Norway, opted for a monocoque design. To ensure
fulfilment of the competition requirements of the chassis, the
monocoque design should provide sufficient torsional stiffness and
absorb the impact energy in case of possible collision. The study reported in this article is based on the requirements for
Formula Student competition. As part of this study, diverse
mechanical tests were conducted to determine the mechanical
properties and performances of the monocoque design. Upon a
comprehensive theoretical study of the mechanical properties of
sandwich composite materials and the requirements of monocoque
design in the competition rules, diverse tests were conducted
including 3-point bending test, perimeter shear test and test for
absorbed energy. The test panels were homemade and prepared with
equivalent size of the side impact zone of the monocoque, i.e. 275
mm x 500 mm, so that the obtained results from the tests can be
representative. Different layups of the test panels with identical core
material and the same number of layers of carbon fibre were tested
and compared. Influence of the core material thickness was also
studied. Furthermore, analytical calculations and numerical analysis
were conducted to check compliance to the stated rules for Structural
Equivalency with steel grade SAE/AISI 1010. The test results were
also compared with calculated results with respect to bending and
torsional stiffness, energy absorption, buckling, etc. The obtained results demonstrate that the material composition
and strength of the composite material selected for the monocoque
design has equivalent structural properties as a welded frame and thus
comply with the competition requirements. The developed analytical
calculation algorithms and relations will be useful for future
monocoque designs with different lay-ups and compositions.", keywords = "Composite material, formula student, ion racing,
monocoque design, structural equivalence.", volume = "10", number = "1", pages = "1-9", }