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Brief

The University of Strathclyde motorsport team (USM) wants to increase their competitiveness at Formula Student (FS) Competitions by creating a lighter, faster race car.

The Chass-A-team has taken on this task to develop a monocoque chassis to realize this goal. The team has access to sponsored composite material but does not have access to facilities that allow for complex manufacturing processes. The project must produce a new car every year according to rules, so timelines for design and production are extremely tight.

Aims & Objectives

Design Aims

  • Rules compliance

  • Ergonomic

  • Interfaces to suspension, roll hoops, bulkhead

  • Accommodation of other components

 

Design Objectives

  • Analyse a variety of composite layups and develop an understanding of manufacturing methods to inform future production of composite components

  • Design and validate SES sections outlined in FS rules 

  • Design and validate a hybrid monocoque and carry out analysis and theoretical comparison regarding physical properties, manufacturing, overall complexity, and a life cycle analysis with respect to the USM21 EV and welded chassis

  • Generation of a comprehensive design methodology for a CFC monocoque

Folded Monocoque

The design developed in this project utilizes the 'cut and fold' technique. Sections of the skin on a cored composite panel are skimmed off, exposing the core. The panel is then folded along this region, prior to additional laminations for reinforcing the 'cut and folded' section. Using this process requires the generation of a net which when folded produces the final part. This necessitates simple, faceted geometry, leading to the angular shape of the monocoque. 

Thesis 

A full copy of Chass-A-Team thesis can be found below