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Alex Hsia Monocoque Overview
1.
Cornell FSAE Monocoque Frame
Overview Alex Hsia Cornell FSAE Monocoque Designer ’14
2.
3.
4.
Layup Order 1 2
3 4 5 6 7 8 9 10 11 12 13 14 Side Impact Bulkhead Support Front Hoop Bracing Main Hoop Support Lip Rear (Shoulder Harness Bar) Bulkhead Engine Top Bottom Back Damper Lip Front Lip Corners Front Lip Thin Lip Corners Rear 1 T800H,45 T800H,45 T800H,45 T800H,45 T800H,45 T800H,45 T800H, 45 T800H, 45 T800H, 45 T800H, 45 T800H, 0 T800H, 0 T800H, 0 T800H, 0 1 2 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800H, 0 T800H, 0 T800H, 0 T800S, 90 T800H, 0 T800H, 0 T800H, 0 T800H, 0 2 3 T800S, 90 T800S, 90 T800S, 90 T800S, 90 T800S, 0 T800H,45 T800H, 45 T800H, 45 T800H, 45 T800S, 0 T800H, 0 T800H, 0 T800H, 0 T800H, 0 3 4 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800H,45 T800S, 0 .5 Core .5 Core T800H, 0 T800S, 90 T800H, 45 T800H, 45 T800H, 45 T800H, 45 4 5 T800H,45 T800H,45 T800H,45 T800H,45 0.75 Core T800H,45 T800H, 45 T800H, 45 T800H, 45 T800H, 45 T800H, 45 T800H, 0 T800H, 45 T800H, 45 5 6 1 Core 1 Core .5 Core 0.75 Core T800H,45 T800S, 0 T800H, 0 T800H, 0 T800H, 0 T800H, 0 .5 Core T800H, 45 T800H, 0 T800H, 45 6 7 T800H,45 T800H,45 T800H,45 T800H,45 T800S, 0 T800S, 0 T800H, 45 T800H, 45 T800H, 0 T800H, 45 T800H, 45 T800H, 0 T800H, 0 T800H, 0 7 8 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800H,45 T800H, 45 0.75 Core T800H, 45 T800H, 45 T800H, 45 T800H, 0 8 9 T800S, 90 T800S, 90 T800S, 90 T800S, 90 T800H,45 0.75 Core T800H, 0 T800H, 45 T800H, 0 T800H, 0 T800H, 45 T800H, 45 9 10 T800S, 0 T800S, 0 T800S, 0 T800S, 0 T800H,45 T800H, 45 T800H, 0 T800H, 0 T800H, 0 T800H, 0 T800H, 45 10 11 T800H,45 T800H,45 T800H,45 T800H,45 T800S, 0 T800H, 0 T800H, 45 T800H, 0 T800H, 45 T800H, 0 T800H, 45 11 12 T800S, 0 T800H, 45 T800S, 90 T800H, 0 T800H, 0 T800H, 0 12 13 T800H,45 T800S, 0 T800H, 45 T800H, 0 13 14 T800S, 0 T800S, 90 T800H, 0 T800H, 0 14 15 T800H,45 T800H, 45 T800H, 45 15 16 T800S, 0 T800H, 0 16 17 T800H,45 T800H, 0 17 18 T800H, 0 18
5.
Material Properties Tests
6.
-100 0 100 200 300 400 500 600 700 800 0 0.005 0.01
0.015 0.02 0.025 Load(lbf) Displacement T800H [05] Tensile Coupons Sample 1 Sample 2 Sample 3 -100 0 100 200 300 400 500 600 700 800 -0.005 0 0.005 0.01 0.015 0.02 0.025 Load(lbf) Displacement T800S [05] Tensile Coupons Sample 1 Sample 2 Sample 3 Tensile strip modulus tests, T800H and T800S Specimens were not broken in order to re-test to check for slippage in jaws
7.
-100 0 100 200 300 400 500 600 700 800 900 0 0.002 0.004
0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02 Load(lbf) Displacement M46J [05] Tensile Coupons Sample 1 Sample 2 Sample 3 -100 0 100 200 300 400 500 600 700 0 0.005 0.01 0.015 0.02 0.025 Load(lbf) Displacement T300 [05] Tensile Coupons Sample 1 Sample 2 Sample 3 Tensile strip modulus tests, M46J and T300
8.
Tensile strip strength
tests, T800H, T800S 0 500 1000 1500 2000 2500 3000 0 0.05 0.1 0.15 0.2 0.25 Load(lbf) Displacement (in) T800H [03] Tensile Coupons 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 Load(lbf) Displacement (in) T800S [03] Tensile Coupons Non-linear curve indicates slipping in jaws
9.
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 M46JSample1 M46JSample2 M46JSample3 M46JSample4 T300Sample1 T300Sample2 T300Sample3 T800HSample1 T800HSample2 T800HSample3 T800HSample4 T800HSample5 T800HSample6 T800HSample7 T800HSample8 T800HSample9 T800HSample10 T800HSample11 T800HSample12 T800HSample13 T800HSample14 T800SSample1 T800SSample2 T800SSample3 T800SSample4 T800SSample5 T800SSample6 T800SSample7 Modulus(Msi) Sample Tested Modulus of
Prepreg Material M46J Sample 1 T300 Sample 1 T800H Sample 1 T800S Sample 1 Tested moduli of materials all much lower than expected. Possible sources of error include slipping in jaws, compliance in testing apparatus, incorrectly designed test strips.
10.
0 50 100 150 200 250 300 350 400 Strength(Ksi) Sample Tested Strength of
Prepreg M46J Sample 5 T800H Sample 12 T800S Sample 5 Tested max strengths are close to expected.
11.
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02 Strain(in/in) Sample Tested Max Strain
of Prepreg M46J Sample 5 T800H Sample 12 T800S Sample 5 Tested max strains are also close to expected.
12.
13.
Rough analysis using
ANSYS ACP Figure 3. 3/4" Solid Carbon Hardpoint Test Panel
14.
Hardpoint Analysis
15.
Panel Bending and
Pullout Tests
16.
y = 28102x
- 187.03 0 1000 2000 3000 4000 5000 6000 0 0.2 0.4 0.6 0.8 Load(lbf) Displacement (in) Hardpoint Test Panels .75" Hardpoint Panel 1 ,75" Hardpoint Panel 2 1" Hardpoint Test Panel Series1 Linear (Series1)
17.
y = 18119x
+ 21.204 0 1000 2000 3000 4000 5000 6000 0 0.2 0.4 0.6 0.8 Load(lbf) Displacement (in) Hardpoint Test Panels .5" Hardpoint Panel 1 .5" Hardpoint Panel 2 Linear (Series1)
18.
Factors of Safety
over Core Failure Front Lower Forward 3.859911 Rear Lower Forward 10.34577 Rear 7.427245 Rear 12.20871 Upper Forward 1.280878 Upper Forward 4.753317 Rear 2.530728 Rear 1.757584 Toe link 11.50272 Toe link 8.651866 Pushrod 1.954779 Pushrod 1.68903
19.
Boundary Conditions for
ANSYS Torsional Stiffness
20.
21.
ANSYS model predicts
4800 ft-lb/deg torsional stiffness
22.
Figure 10. "Lozenging"
Effect
23.
Figure 11. Vector
Principal Elastic Strain around Lip
24.
y = 1538.5x -1000 -800 -600 -400 -200 0 200 400 600 800 1000 -0.6
-0.4 -0.2 0 0.2 0.4 0.6 Torque(ft-lb) Angular Displacement (deg) Hub-Hub Torsional Stiffness
25.
y = 4083.7x -1000 -800 -600 -400 -200 0 200 400 600 800 1000 -0.2
-0.15 -0.1 -0.05 0 0.05 0.1 0.15 0.2 0.25 Torque(ft-lb) Angular Displacement (deg) Monocoque Torsional Stiffness
26.
27.
Design goal: frame stiffness
10x overall torsional wheel rate Overall torsional wheel rate 120 ft-lb/deg vehicle 1553.03 ft-lb/deg suspension 2500 ft-lb/deg 12.5x wheel rate frame 4100 ft-lb/deg 20.5x wheel rate
28.
ANSYS Corner Brake
Bump
29.
Factor of safety
of >5 everywhere on body. Max strain of 18e-3 strain obtained from tensile tests
30.
Stress Contour
31.
patch load 217.5
lbf upright height 6.7 in hardpoint stiffness 28000 lbf/in top A-arm load 89.74449 lbf lower A-arm load 309.9383 lbf top hardpoint deflection 0.003205 in lower hardpoint deflection 0.011069 camber change at max corner 0.122069 deg Camber Compliance due to hardpoints
32.
3 Point Bend
Test Results y = 6080.6x - 43.689 0 500 1000 1500 2000 2500 0 0.1 0.2 0.3 0.4 0.5 0.6 Load(lb) Displacement (in) 3 Point Bend C y = 6946.3x - 415.24 0 500 1000 1500 2000 0 0.1 0.2 0.3 0.4 0.5 0.6 Load(lb) Displacement (in) 3 Point Bend A y = 7586.5x - 57.412 0 500 1000 1500 2000 2500 0 0.1 0.2 0.3 0.4 0.5 0.6 Load(,bf) Displacement (in) 3 Point Bend B
33.
Manufacture Pictures
34.
Core Sections and
Core Splice
35.
Figure 14. Three
part cure (2 autoclave, 1 postcure) for improved surface finish
36.
Cured Laminate
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