Final Bachelor thesis Presentation

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GSET 2015

Design and Analysis of Composite Chassis for Shell Eco Marathon Prototype vehicle 2016 using Finite Element Analysis

Presenter: Mohammed OmerSupervisor: Dr.-Ing. Emmanouil Bouzakis

Affiliated to

Affiliated to1

Table of ContentsIntroductionProblem Statement and AimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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IntroductionShell Eco Marathon CompetitionDiesel Prototype

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Table of ContentsIntroductionProblem Statement and AimAimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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Problem Statement & AimsHigh weight of previous chassisInsufficient torsional stiffnessLow fuel efficiency

Design composite chassisLightweight and stiff

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Table of ContentsIntroductionProblem Statement and AimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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Chassis Design ConceptsSpace frame Ladder frameMonocoque

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Material Comparison MaterialDensity, (g/cm3)Tensile Strength, (MPa)Tensile Modulus, E (GPa)Specific Strength, /Specific Modulus, E/Steel7.8130020016726Aluminium2.813507312526Titanium490010822527Magnesium1.82704515025E glass*2.111007552436Aramid1.32140045106134IM Carbon1.5125001511656100HM Carbon1.5415502121006138

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Sandwich Panels

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Table of ContentsIntroductionProblem Statement and AimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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ModellingHand sketches and Mock-up3D modellingCompact packaging

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Simulation Setup - 1

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Composite Layup

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Vertical Bending Simulation

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Use of Remote Points for Suspension Simulation

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Torsional Stiffness Analysis

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Table of ContentsIntroductionProblem Statement and AimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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Analytical Validation

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Bending Results

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Torsional Analysis Results

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Optimisation of Suspension Points

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Torsional Failure Map

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Belt Harness Test

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Investigating Effect of Changing Core Thickness

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Investigating Effect of Changing Core Thickness - ResultsNomex core (mm)Max. deformation (mm)Max. Stress (MPa)Max combined IRFFailure (Yes/No)920.14 1461.13Yes1217.931230.957No1516.39107.50.805No2013.88800.662No2511.95670.679No3010.1761.20.471No

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Utilizing Engine as Chassis Member

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Vertical Bending

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Torsional Test

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Investigating Effect of Core Thickness While Using Engine as Chassis MemberNomex core (mm)Max. deformation (mm)Max. Stress (MPa)Max combined IRFFailure (Yes/No)97.00667.90.547No126.2462.40.457No155.7953.40.396No205.2752.60.330No254.81470.284No304.42420.301 (at SP)No

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GSET 2015 Chassis

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Bending Analysis of GSET Chassis 2015

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Torsional Analysis of GSET Chassis 2015

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Table of ContentsIntroductionProblem Statement and AimLiterature ReviewMethodologyResults and DiscussionConclusion and Outlook

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AchievementsAchievements55% weight reduction2 times stifferCompact packagingCombination of base and chassis

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Further Work and RecommendationsDetermination of exact material propertiesAdhesive between CFRP & metal analysisComposite layup optimisationSimulation validation with physical testsUsing powerful PC for finer meshing and higher accuracyCombining work with body team to achieve monocoque design35

ReferencesRules and regulations. Shell Global. [Online] [Cited: 20 March 2015.] http://www.shell.com/global/environment-society/ecomarathon/for-participants/general-information/rules.html.Riley, W. B., George, A. R. Design, Analysis and Testing of a Formula SAE Car Chassis. SAE Technical Paper. USA: Cornell University, 2002. HexWeb(TM) HONEYCOMB SANDWICH DESIGN TECHNOLOGY. [Pdf] s.l.: Hexcell Composites, 2000.Eurenius, C. A., Danielsson, N., Khokar, A., Krane, E., Olofsson, M., Wass, J. Analysis of Composite Chassis. Bachelor Thesis. Goeteburg, Sweden: Chalmer's University of Technology, 2013.

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Thank you37