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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. - PowerPoint PPT Presentation
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Creating a Future for Engineers
Formula Student Germany
Wet laminated CFRP monocoque
Manuel Baumann amz.ethz.ch
Creating a Future for Engineers
Introduction
Creating a Future for Engineers
Mold manufacturing
Part manufacturing
Additions
Potential
Bill of Material
Timeline
Index
Creating a Future for Engineers
Positive molds
Laminated negativ molds
Wet laminated monocoque
Bonded halves
Mold manufacturing – Concept
Creating a Future for Engineers
Mold manufacturing – Molding material
MDF PU Aeroboard 70
Density 800 kg/m ³ 630 kg/m ³
Thermal expansion 7.5*10-6 46.8*10-6
Thermal resistance >100° 93°
Cost 500 EUR/m³ 8000 EUR/m³
Disadvantage MDF
Inhomogeneous density over thickness
Sensitive to humidity
Creating a Future for Engineers
Mold manufacturing – Positive molds Bonding
Creating a Future for Engineers
Mold manufacturing – Positive molds Milling
Creating a Future for Engineers
Mold manufacturing – Positive molds Sanding
Creating a Future for Engineers
Mold manufacturing – Positive molds Priming
Creating a Future for Engineers
Mold manufacturing – Positive molds Bolts for insert positioning
Internal thread
Creating a Future for Engineers
Material choice: CFRP
Alternative material: GFK
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer:
Epoxy
Fibreglas
Flocs
Thixotropiermittel
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
600 gr/m²
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Demoldi
Mold manufacturing – Negative molds
Creating a Future for Engineers
Formenharz P
Connection Layer
6 Layers Carbon Fibre
Vacuum
Demold
Finished mold
Mold manufacturing – Negative molds
Creating a Future for Engineers
Core material:
Divinycell HP 60 foam
Insert material
Carbon and wood
Part Manufacturing – Material choice
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Part manufacturing – Monocoque halves
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Vacuum bonding
Sanding
Part manufacturing – Monocoque halves
Creating a Future for Engineers
Mold release agent
Frecote
Part manufacturing – Monocoque halves
Creating a Future for Engineers
Mold release agent
Frecote
Resin: Hexion L 235
Hardener L236
Microballons for filling the gaps
Part manufacturing – Monocoque halves
Creating a Future for Engineers
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
Creating a Future for Engineers
Bonding
the halves
Part manufacturing – Joining upper and lower halves
Creating a Future for Engineers
Roll hoop
Part manufacturing – Additional structural parts
Creating a Future for Engineers
Roll hoop
Rib
Part manufacturing – Additional structural parts
Creating a Future for Engineers
Weight: 21kg (without rollhoops)
Part manufacturing – Result
Creating a Future for Engineers
Painting
Degreasing
Primer
Sanding
White color
Sanding
White color
Clear varnish
4kg
Part manufacturing – Additional structural parts
Creating a Future for Engineers
Prepreg Monocoque: -Temperature resistant resin for negative molds
-Same manufacturing process
Advantage: Less weight, better surface, no painting needed
Additions – Potential
Creating a Future for Engineers
Additions – Bill of material
Material Amount Price
CFRP 600g/m2 for negative molds 30m2 1200EUR
CFRP 250g/m2 for monocoque 40m2 1400EUR
Foam Core 5mm 6m2 300EUR
MDF 0.8m3 500EUR
Resin 35kg 600EUR
Vacuum material 300EUR
Total 4300EUR
Creating a Future for Engineers
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
Creating a Future for Engineers
05. – 09. August 2009
See you at Hockenheim