Design And Manufacture Of Racing Car Body Prototype Made Of Carbon Fiber Composite

Carbon fiber reinforced plastic has very high specific strength and stiffness that applied to replace the traditional steel automobile body cover,it can reduce the weight of 40%~60%,which is equivalent to the original weight of 1/3 ~ 1/6.Based on the FSAE body cover as an example,the article makes a research on design,test and manufacture of the body cover and explores the feasible of the CFRP in order to achieve the purpose of lightweight.Based on the modeling design theory of the NURBS curve/surface,considering shape design influence factors such as the layout of the car and ergonomics and aerodynamic,CATIA is used to set up the body cover model of FSAE.A variety layers design schemes of body cover is raised up which based on the design ability of the carbon fiber reinforced composites.In order to ensure the automobile body covers of CFRP with good impact resistance,drop impact finite element model is set up which based on the Hashin failure criterion and stiffness degradation method and the FE results is compared with the pre-experimental result which verify the validity of FE model.Combining with different layer thickness,layer ratio and layer angle proportion,different layers design schemes are simulated.Considering the effect of lightweight and the feasibility of the actual layers building,[(0,90)]4 layer perform with good loading capacity and impact resistance.Impact test is done to the [(0,90)]4 layer lamina coming with the results that the lamina absorbed 36.78 J energy with global failure,showing good impact resistance.The layers scheme is suitable for the FSAE racing car body cover.Finally,the body cover of the FSAE racing car is manufactured by VARTM with the [(0,90)]4 layer and assembled to the FSAE racing car.The joint connection is designed and the strength is checked.FSAE racing car attended the Formula Student 2015.