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Formula Student Germany

Formula Student Germany. Wet laminated CFRP monocoque. Manuel Baumann amz.ethz.ch. Introduction. Mold manufacturing Part manufacturing Additions Potential Bill of Material Timeline. Index. Positive molds Laminated negativ molds Wet laminated monocoque Bonded halves.

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Formula Student Germany

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  1. Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch

  2. Introduction

  3. Mold manufacturing Part manufacturing Additions Potential Bill of Material Timeline Index

  4. Positive molds Laminated negativ molds Wet laminated monocoque Bonded halves Mold manufacturing – Concept

  5. Mold manufacturing – Molding material Disadvantage MDF • Inhomogeneous density over thickness • Sensitive to humidity

  6. Mold manufacturing – Positive molds • Bonding

  7. Mold manufacturing – Positive molds • Milling

  8. Mold manufacturing – Positive molds • Sanding

  9. Mold manufacturing – Positive molds • Priming

  10. Mold manufacturing – Positive molds • Bolts for insert positioning • Internal thread

  11. Material choice: CFRP Alternative material: GFK Mold manufacturing – Negative molds

  12. Formenharz P Mold manufacturing – Negative molds

  13. Formenharz P Connection layer: Epoxy Fibreglas Flocs Thixotropiermittel Mold manufacturing – Negative molds

  14. Formenharz P Connection layer 6 Layers carbon fibre 600 gr/m² Mold manufacturing – Negative molds

  15. Formenharz P Connection layer 6 Layers carbon fibre Vacuum Mold manufacturing – Negative molds

  16. Formenharz P Connection layer 6 Layers carbon fibre Vacuum Demoldi Mold manufacturing – Negative molds

  17. Formenharz P Connection Layer 6 Layers Carbon Fibre Vacuum Demold Finished mold Mold manufacturing – Negative molds

  18. Core material: Divinycell HP 60 foam Insert material Carbon and wood Part Manufacturing – Material choice

  19. 2 core layers of 5mm Heat bending Part manufacturing – Monocoque halves

  20. 2 core layers of 5mm Heat bending Vacuum bonding Sanding Part manufacturing – Monocoque halves

  21. Mold release agent Frecote Part manufacturing – Monocoque halves

  22. Mold release agent Frecote Resin: Hexion L 235 Hardener L236 Microballons for filling the gaps Part manufacturing – Monocoque halves

  23. Procedure 4 layers CFRP Placing core / inserts 12 h vacuum 4 inner layers CFRP 15 h vacuum 12-20 h curing at 80° Part manufacturing – Monocoque halves

  24. Bonding the halves Part manufacturing – Joining upper and lower halves

  25. Roll hoop Part manufacturing – Additional structural parts

  26. Roll hoop Rib Part manufacturing – Additional structural parts

  27. Weight: 21kg (without rollhoops) Part manufacturing – Result

  28. Painting Degreasing Primer Sanding White color Sanding White color Clear varnish 4kg Part manufacturing – Additional structural parts

  29. Prepreg Monocoque: -Temperature resistant resin for negative molds -Same manufacturing process Advantage: Less weight, better surface, no painting needed Additions – Potential

  30. Additions – Bill of material

  31. Important: Well organiced workspace for laminating and sanding 2-4 people needed during laminating (due to little pot-life) We used 8 weeks, mostly one person for positive molds, negative molds and monocoque Additions – Timeline

  32. See you at Hockenheim 05. – 09. August 2009

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