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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 to

Table of Contents• Introduction

• Problem Statement and Aim• Literature Review

• Methodology• Results and Discussion

• Conclusion and Outlook2

Introduction• Shell Eco Marathon

Competition• Diesel Prototype

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Table of Contents• Introduction

• Problem Statement and Aim• Aim

• Literature Review• Methodology

• Results and Discussion• Conclusion and Outlook

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Problem Statement & Aims• High weight of previous chassis• Insufficient torsional stiffness• Low fuel efficiency

• Design composite chassis• Lightweight and stiff

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Table of Contents• Introduction

• Problem Statement and Aim• Literature Review

• Methodology• Results and Discussion

• Conclusion and Outlook6

Chassis Design Concepts• Space frame • Ladder frame• Monocoque

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Material Comparison Material Density, ρ

(g/cm3)Tensile

Strength, σ (MPa)

Tensile Modulus, E

(GPa)

Specific Strength,

σ/ρ

Specific Modulus,

E/ρ

Steel 7.8 1300 200 167 26

Aluminium 2.81 350 73 125 26

Titanium 4 900 108 225 27

Magnesium 1.8 270 45 150 25

E glass* 2.1 1100 75 524 36

Aramid 1.32 1400 45 1061 34

IM Carbon 1.51 2500 151 1656 100

HM Carbon 1.54 1550 212 1006 138

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Sandwich Panels

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Table of Contents• Introduction

• Problem Statement and Aim• Literature Review

• Methodology• Results and Discussion

• Conclusion and Outlook10

Modelling• Hand sketches and

Mock-up• 3D modelling• Compact 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

Torsional stiffness,and Vertical displacements Track width 16

Table of Contents• Introduction

• Problem Statement and Aim• Literature Review

• Methodology• Results and Discussion• Conclusion and Outlook

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Analytical Validation

Simply Supported Beam Fixed Supported Beam Analytical ANSYS Error (%) Analytical ANSYS Error (%)δ (mm) 202.56 202.71 +0.074% 53.03 52.97 -0.06% (MPa) 232.63 242.11 +3.92% 116.32 119.75 +2.86% (MPa) 0.1368 0.155 +11.74% 0.1368 0.15 +8.8%

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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 - Results

Nomex core (mm)

Max. deformation (mm)

Max. Stress (MPa)

Max combined IRF

Failure (Yes/No)

9 20.14 146 1.13 Yes

12 17.93 123 0.957 No

15 16.39 107.5 0.805 No

20 13.88 80 0.662 No

25 11.95 67 0.679 No

30 10.17 61.2 0.471 No

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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 Member

Nomex core (mm)

Max. deformation (mm)

Max. Stress (MPa)

Max combined IRF

Failure (Yes/No)

9 7.006 67.9 0.547 No

12 6.24 62.4 0.457 No

15 5.79 53.4 0.396 No

20 5.27 52.6 0.330 No

25 4.81 47 0.284 No

30 4.42 42 0.301 (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 Contents• Introduction

• Problem Statement and Aim• Literature Review

• Methodology• Results and Discussion

• Conclusion and Outlook33

AchievementsAchievements• 55% weight reduction• 2 times stiffer• Compact packaging• Combination of base and chassis

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Further Work and Recommendations• Determination of exact material properties• Adhesive between CFRP & metal analysis• Composite layup optimisation• Simulation validation with physical tests• Using powerful PC for finer meshing and higher

accuracy• Combining work with body team to achieve

monocoque design

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References• Rules 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 you

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