BGR CFRP Monocoque challenge
Current situation
The integration of CFRP materials into automotive designs presents challenges related to compatibility, performance, and safety, necessitating a careful transition from a Chromolly tubular space frame to a CFRP monocoque. Key considerations include determining the optimal geometry for suspension, aerodynamic features, and the placement of components like the battery pack and sensors, all while adhering to FSAE safety protocols. Additionally, decisions regarding the production method—whether to use preimpregnated carbon fibers or an injection method—must be made early to facilitate timely production. The development process involves creating molds and plugs from suitable materials, ensuring that all assemblies can be connected without compromising structural integrity, and maintaining strict adherence to budget constraints and sourcing of materials.
Disadvantages
a tubular steel frame is typically heavier, more robust and has a simpler geometry not allowing good aerodynamic features.
Ideal final result
Establish a cost-effective production process for CFRP structures that allows for efficient material sourcing and manufacturing, including the selection of suitable materials for molds and plugs.
Gaps
there is currently no infastrucure in the team to build the monocoque, no knowledge of composite engineering, a lack of tools in-house so many of the work will have to be outsourced, and much of the integrating components such as sensors and suspension are not in research stage yet
Problem statement
Insufficient understanding of CFRP integration, coupled with the absence of necessary tools and infrastructure, poses significant challenges in developing a compliant and efficient CFRP monocoque chassis for automotive applications.
Anatoly Agulyansky
This is a great project showing that previous experience is important and can be used to create the future
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