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Technical Paper

Production of a Composite Monocoque Frame for a Formula SAE Racecar

2013-04-08
2013-01-1173
A carbon-fiber-reinforced plastic (CFRP) monocoque racecar frame was designed and constructed by students for the 2012 Formula SAE (FSAE) collegiate design series competition. FSAE rules require that the monocoque frame have strength equal to or greater than the traditional steel space frames that they replace. The rules also specify minimum values for perimeter shear strength, main roll hoop attachment strength and driver harness attachment (pullout) strength. Overcoming limitations imposed by locally available finite element analysis tools, a variety of tests were devised to determine required laminate thicknesses and layup orientations. These included perimeter shear tests, pin shear tests, three-point bend tests and tensile tests. Based on the results of these tests, a sandwich construction using composite skins fabricated from carbon/epoxy prepreg and aluminum honeycomb core was selected.
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