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UQ-Deisgn of a CF Composite Chassis Thesis

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  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    Benjamin Lii4/26 Durham St.

    St. LuciaQLD, 4067

    30 th October 2009

    Professor D.J. MeeHeadSchool of Mechanical & Mining EngineeringUniversity of QueenslandQueensland 4072

    Dear Sir,

    I hereby submit my Thesis titled Design and Manufacture of a Composite Monocoque Chassis forconsideration as partial fulfilment of the Bachelor of Engineering degree.

    All the work contained within this Thesis is my original work except where otherwise acknowledged.

    I understand that this thesis may be made publicly available and reproduced by the University ofQueensland unless a limited term embargo on publication has been negotiated with a sponsor.

    Yours sincerely

    Benjamin LiiStudent ID: 41013580

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    1. I .......................................................................................................................................... 1

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    1.2. T A ......................................................................................... ................................................ 3

    1.3. T O ............................................................................................................................... 3

    1.4. T S .................................... .................................................................................................. 3

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    1.6. A R C .................................................................................................................. 8

    2. L R ................................................................................................................................ 10

    2.1. C M A I ................................................................ 10

    2.2. M D P ........................................................................................................ 11

    2.3. S S H C ......................................................... ..................... 13

    2.4. C J ....................................................................................................................... 15

    2.5. L I I ..................................................................................................... 16

    2.6. F E A C M ........................................................................ 18

    3. D A ................................................................................................................................. 21

    3.1. P P ................................................................................................................................. 22

    3.2. S ...................................................................................................................................... 22

    3.3. M ................................................................................................................................... 24

    3.4. B ....................................... .................................................................................................. 24

    3.5. R .................................................................................................................................... 25

    4. D ............................................................................................ ...................................................... 26

    4.1. G D L A .............................................................................................. 26

    4.2. S P S ........................................................................................................... 28

    4.3. I D T ............................................................................................................ 30

    P ............................................................................................................................................ 31

    R ................................................................................................................................................. 34

    A D M ....................................................................................................... 37

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    4.4. P G ............................................................................................................................. 39

    4.5. B T FEA V ............................................................................................... 43

    T P .................................................................................................................................... 43

    R ................................................................................................................................................. 45

    A ............................................................................................................................................... 46

    4.6. D FEA M ........................................................................................................ 48

    4.7. E FEA R ....................................................................... ..................................... 53

    4.8. S F M .......................................................................... ................................... 57

    5. M .................................................................................................................................... 58

    5.1. M ....................................... ................................................................................................. 58

    5.2. L U ........................................................................................... ............................................... 61

    6. T ........................................................................................... ...................................................... 63

    7. O F D ..................................................................................................................... 64

    7.1. S F ........................................................................................................ 65

    7.2. S D .................................................................................................................... 66

    8. D E ................................................................................................................................ 68

    9. C ..................................... ...................................................................................................... 69

    R .................................................................................................................................................. 70

    A ................................................................................................................................................. 72

    A A. I ............................................................................................................ 72

    A B. T S A C S F C .............................................. 73

    A C. M D MTM56/HTA5131 ................................................................................... 74

    A D. M D EC A H C ............................................................ 75

    A E. C O T ..................................................................................................... 76

    A F. F T ................................................................................................................. 77

    F 1 T (M S R ) ............................................. 5F 2 T ..................................................... 6F 3 T

    (U C , 2002) ....................................................................................... 7F 4 T .............................................................................................................. 9F 5 F F1 (S , F 1 C E , 2009) .................................................................................................................................................................... 12

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    F 6 S , F1 (S , F 1 C E , 2009) ................................................................... 13

    F 7 F C H (H , 2005) ........................................ 16F 8 O (H& P , 2009) ............................................................................................................................................... 17

    F 9 N (H & P , 2009) ..... 18F 10 R 1 .................................................................................. 23F 11 FEA 2009 ...................................................................... 26F 12 S , (S , F 1 C E ,2009) ........................................................................................................................................................... 28F 13 P (P , 2005) ................................................................................. 29F 14 A .............................................. 32F 15 I .................................................................................................... 32F 16 I ............................................................................................................................... 33F 17 I ................................................................................................................ 34F 18 I .................................... 36F 19 S ......................................... 36F 20 F ........................................ 38F 21 E ................................................................................................ 40F 22 R , .................................................................................................................................................................... 40F 23 CAD .............................................................................. 42F 24 B .................................................................................................... 43F 25 FEA ................................................................................................................... 44F 26 4 ................................................................................................. 45F 27 R 2 1 ...................................................................................................... 45F 28 4 FEA ........................................................................... 46F 29 B ....................................................................................... 48F 30 P ,

    ...................................................................................................................................................... 49F 31 CAD FEA ......................................................................................................... 50F 32 L ............................................................................................................... 51F 33 P , 0.5 ............... 53F 34 FEA , ................................................................ 55F 35 T

    .................................................................................................................................................. 57F 36 T EPS ......................................................................................... 59F 37 T ............................................... 59F 38 T , . ...................... 60F 39 T ........................... 60F 40 T .......................... 62

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    F 41 T ................................................................. 62F 42 C (B , 2005) .................................................................................... 63F 43 F ................................................................................................................................. 64

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    T FEA . S

    FEA . B

    , 2400 N

    1.23. H FEA

    ,

    FEA . T

    , ,

    . A H

    .

    20

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    40

    21

    22 ,

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    41

    A . I

    2009 . I

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    . I

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    , .

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    . T

    5 24. A

    . T .

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    23 A

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    4.5. B

    55%

    T

    . T

    EN 6061 (A

    ASTM

    ASTM D 7250

    650 75

    5

    10 ECM 6.4 80 10 3003

    . T

    24 B

    43

    FEA . T

    . T

    .

    .

    ,

    ASTM D 7250 (ASTM

    D I A E , 199

    . T

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    ,

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    4 . B

    ,

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    . T

    S

    400

    610

    I , 2006)

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    5.

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    B S 7

    . T

    . T

    . T

    . T FEA

    26. T S 7 S

    4.6 FEA . T FEA

    27.

    25 A

    T FEA 10

    1,200 N . A 10 L

    V D T (LVDT) 100N

    . T FEA

    .

    T I

    . I 100 N

    . I LVDT

    . T .

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    45

    26 4

    27 2 1

    10

    8

    6

    4

    2

    0

    1 2 0

    3 9

    5 8

    7 7

    9 6

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    2 2 9

    2 4 8

    2 6 7

    2 8 6

    3 0 5

    3 2 4

    3 4 3

    3 6 2

    3 8 1

    4 0 0

    4 1 9

    4 3 8

    4 5 7

    4 7 6

    4 9 5

    5 1 4

    5 3 3

    5 5 2

    ,

    B 2 1

    2 1

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    46

    28 4 A

    A ,

    . H ,

    . H

    ,

    . I .

    T

    FEA. F FEA . T

    FEA

    . T ;

    L /P T , P M , C S M C T .

    0

    100

    200

    300

    400

    500

    600

    700

    800

    0.000 2.000 4.000 6.000 8.000 10.000

    ,

    ,

    4 B

    B 1 T 1

    B 1 T 2

    B 2 T 1

    B 2 T 2

    P FEA

    C FEA

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    47

    T , /

    . T .

    T ,

    ,

    , , .

    A FEA ,

    , ,

    .

    T FEA

    . I

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    , .

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    . T

    :

    , E = B , (GP )

    =

    E = 237 GP ( HTA 5131 )

    E = 3.6 GP ( MTM56 )

    A ,

    . T

    . T

    .

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    48

    29 B

    F 0.55 66 GP ,

    65 GP . A 49.9 MP ,

    0.41. O MTM56

    0.53. T

    0.55

    . T ,

    . T

    FEA .

    4.6. T 8

    S 7. T , ,

    ,

    .

    49.9

    66.0

    0.0

    20.0

    40.0

    60.0

    80.0

    100.0

    120.0

    140.0

    160.0

    0 0.2 0.4 0.6 0.8 1 1.2

    ,

    B

    U 2 2

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    49

    T FEA . F

    . T IGES

    CAD FEA . T

    FEA

    CAD . T

    .

    I

    . T

    :

    A , 11 22 . A

    ,

    .

    T

    .

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    , .

    T S 7

    . A

    ,

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    30 ,

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    50

    31 A A

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    51

    A 4

    1

    (S 7, 2008). T

    8 . T .

    O . M

    . I

    . T

    . T 0, 45, 0, 45, 0

    .

    32

    C . M

    . T 6

    . E

    . T .

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    52

    R ,

    . T ,

    , . T

    ,

    , .

    F . T

    , . T

    . M

    .

    6

    A , 2 A , 2 A , 2

    A 9.81 0 0

    A A 9.81 14.72 0

    A + A 9.81 14.72 14.72

    A 9.81 0 14.72

    B 9.81 0 14.72

    B + B 9.81 14.72 14.72

    B B 9.81 14.72 0

    B A 29.43 0 0

    7 A

    71,922 52

    B 151 99

    23,815

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    53

    4.7. O FEA

    . I

    . T , , ,

    .

    33 , 0.5

    L ,

    T S 7. A

    . I

    ,

    .

    T .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    54

    I ,

    0.5 . H ,

    0.2 . T ( 18)

    0.2 (1,785 N).

    8

    . .

    43.01 35.48 42.84 35.48

    A 186.01 153.72 186.05 153.72

    A + 27.43 20.88 26.60 20.88

    17.53 14.19 16.90 14.19

    B + 21.39 17.59 21.09 17.59

    B 36.17 24.42 31.52 24.42

    B 14.33 11.82 14.28 11.82

    T . T

    . H

    ,

    . T

    FEA

    . T .

    D

    . T

    , . A

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    55

    . T

    M T ,

    1000.

    .

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    . F

    .

    34 A ,

    T

    . B , .

    T , .

    T . T

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    56

    . T , . T

    .

    9

    , ,

    ,

    ,. / /

    : : 40 1.94E 04 2.41E 01 4.61E 02 1.055 22,875

    : : 37 1.35E 04 2.41E 01 3.20E 02 0.755 23,560

    : : 35 2.38E 04 2.64E 01 5.18E 02 1.055 20,386

    : : 33 1.86E 04 2.64E 01 4.03E 02 0.755 18,723

    : : 39 1.94E 04 2.41E 01 4.62E 02 1.055 22,859

    : : 38 1.31E 04 2.41E 01 3.11E 02 0.755 24,260

    : : 36 2.38E 04 2.64E 01 5.17E 02 1.055 20,397

    : : 34 1.86E 04 2.64E 01 4.03E 02 0.755 18,725

    L N :

    ( / ) : ( / ) : ( / )

    18,723

    A 21,473

    T

    . T 1000 N

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    I 21,473 N. / / ,

    4 . I

    . C ,

    .

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    57

    35

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    . D

    .

    ; . T

    .

    T

    (A , 1969). I

    . U FEA

    . T 74.9 MP

    .. F

    FEA 52.82 MP

    . T 1.42. T

    .

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    58

    5. T

    LSM . C J

    . T

    . I

    .

    5.1. T . T

    . T 2 ,

    , . F

    , .

    F

    , . H

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    .

    O EPS 2 . T

    . O

    . C

    . O , CNC

    . T

    . M

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    59

    36

    37

    T ,

    , . O ,

    ,

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    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    60

    38 , .

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    . T

    . T . A

    ,

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    .

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  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    61

    5.2. O

    . H

    . O ,

    . T CNC ,

    .

    P ,

    . S

    . O

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    . T

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    .

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    . T

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    . O

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    62

    40

    41

    S LSM A C

    . F

    , LSM A C

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    63

    6. O

    ,

    . T . T

    ; . T

    . T

    .

    42 (B , 2005)

    I . I

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    64

    7. T . T

    6 M8 . A

    / , .

    43

    I

    . T ,

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    65

    7.1. T

    .

    10

    , 1,510.0 1,479.5

    , 1,145.4 1,145.4

    , 711.5 825.4

    , 18.35 22.97

    , . / / 21,473 6,821

    T

    . A

    .

    11

    4.80

    A 3.09

    A 2.02

    5.46

    B 2.04

    0.96

    18.35

    A ,

    . T

    . T F SAE ,

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    66

    7.2.

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    67

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    68

    8. T

    . T

    .

    T

    . T ,

    . T

    ,

    .

    F , , . T

    . A

    50% . T

    . M

    .

    T FEA

    . T

    , FEA

    . ,

    ,

    .

    F , , . T

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    69

    9. T . H

    . T ,

    . I ,

    .

    A .

    M

    FEA

    . A FEA 4

    . A

    . I

    .

    I

    . H

    . A .

    T

    H

    ,

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    70

    A D I A E . (1995, N 1). AECMA PRED6061A S F R P T M D S F S 4P B .

    A , H. G. (1969). . L : P P .

    A E . (2009). . R S 13, 2009, H AP I : :// . . /

    ASTM I . (2006). ASTM D7250 / D7250M 06 S P D SB F S S . ASTM I .

    B , E. J. (2008). . B R : CRC P .

    B , L. M. (2005). . S . L : T U Q .

    B , T. (1997). , , , . L : C & H .

    B , P., C , B., & B , J. J. (2008). N . , 1077 1092.

    F1 C . (2008). 1 . R M 13, 2009, F1C : :// . 1 . / / /1843/389/

    G , D., & H , S. V. (2007). (2 E .). B R :

    CRC P .

    G , T., & A , M. (2009, O 16). H P S . (B. L , I )

    H , M., & H , . (2008). A . 2 , 709 713.

    H , S., & P , M. (2009). F . , 575 588.

    H . (2005, D ). . R J 26, 2009, H . : :// . . /NR/ /7F70671B ED6E 4562 9659ABA426A7453F/0/R H S G .

    LSM. (2009, M 25). M D . (B. L , I )

    M S R . ( . .). 32. R O 15, 2009, M S R ::// . . /32 .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    71

    M , G. (2006). C . , 20 24.

    N , N. K., R , G. N., A , U., R , K. A., P , S. A., & S , V. (2009). S S C I : E S . , 639 648.

    P , J. (2005). . R A 12, 2009,

    C M D : :// . . . / / 4150/ / 1.

    Q , P., & , J. (2005). T S S C H C E M . , 159 172.

    SAE I . (2008). 200 . R M 28, 2009, F SAE A::// . . . / / /2009/02/2009 1.

    S , G. (2007). F . 14 , 321 348.

    S , G. (2009). F 1 C E . , 2 28.

    S A E A . (2009). . R M 28, 2009, :// . . . /

    S , K. I., C , J. ., K , J. H., C , J. H., & K , K. S. (2008). A . 6 , 107 113.

    S 7. (2008). 7 . R J 11, 2009, S 7 F E A FEAS : :// . 7. /

    T , O. T. (1998). S ' ' ' ' :

    . , . 40 , 159 174.

    U C . (2002, F 25). . RO 25, 2009, M S P : ://

    . . . . / / / / .

    , M., & S , R. (2002). A . , 1457

    1460.

    . (2009). . R O 24, 2009, :

    :// . . / /M

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    73

    .

    ,

    ,

    ,

    ,

    . / /

    : : 40 6.04E 04 2.41E 01 1.44E 01 1.055 7349

    : : 37 4.45E 04 2.41E 01 1.06E 01 0.755 7139

    : : 35 7.00E 04 2.64E 01 1.52E 01 1.055 6938

    : : 33 5.84E 04 2.64E 01 1.27E 01 0.755 5957

    : : 39 6.10E 04 2.41E 01 1.45E 01 1.055 7278

    : : 38 4.44E 04 2.41E 01 1.05E 01 0.755 7161

    : : 36 7.10E 04 2.64E 01 1.54E 01 1.055 6839

    : : 34 5.89E 04 2.64E 01 1.28E 01 0.755 5907

    L N :

    ( / ) : ( / ) : ( / )

    5907

    A 6821

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    74

    . 56/ 5131

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    75

    .

  • 8/9/2019 UQ-Deisgn of a CF Composite Chassis Thesis

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    76

    .

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    .