Carbon Fibre Components

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    CARBON FIBRE

    COMPONENTSIN

    AUTOMOBILES

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    CONTENTS

    Introduction

    Types of carbon fibre sheets used in automobiles

    Types of carbon fibre components in Automobiles

    Comparison of carbon fibre parts with Al alloy parts

    Manufacturing of carbon fiber parts

    Advantages of carbon fiber parts

    Disadvantages of carbon fiber parts

    Conclusion

    References

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    Introduction

    Carbon fibre, alternatively graphite fibre or CF,is a material consisting of fibres about 5-10 min diameter and composed mostly of carbonatoms.

    The carbon atoms are bonded together incrystals that are more or less aligned parallel tothe long axis of the fibre.

    The crystal arrangement gives the fibre highstrength to volume ratio. Several thousandcarbon fibres are bundled together to form atow, which may be woven into a fabric

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    Structure of carbon fibre

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    The properties of carbon fibres, such as highstiffness, high tensile strength, low weight,

    high chemical resistance, high temperature

    tolerance and low thermal expansion.

    This makes them very popular in Aerospace,

    Civil engineering, Military, and Motorsports,along with other competition sports.

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    Types of carbon fibre sheets used in

    automobiles

    Pre peg carbon fibre sheet

    These are double sided high gloss carbon fibre sheetdesigned for applications where the highest strengthand best possible surface finish are required (formerlyknown as robotics grade ).

    Wet lay carbon fibre sheet

    Genuine carbon fibre flat sheet, single sided gloss in a

    range of sizes and thicknesses.

    Foam-Cored Carbon fibre sheet

    Vacuum pressed ultra-light single-sided carbon fibre

    4mm sandwich panel in a range of large sheet sizes.

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    Types of carbon fibre components in

    Automobiles

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    Carbon fibre parts

    Hood

    Rear spoiler

    Windshield frame

    Door panels

    Engine cover

    Wheels

    Body panels

    Roofs

    Doors

    Removable hard top

    Cockpit

    Floor

    A pillar

    Front crash guard

    Body and structures

    Dash panels

    Propeller shaft

    Steering wheel

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    Comparison Of Carbon Fibre parts

    With Aluminium parts

    1.Weight :

    Carbon fibre parts weigh significantly less than aluminum

    parts of the same size this means bike/car will weigh less

    and will take less effort to go faster.

    2. Strength:

    Unlike aluminium, the carbon fibre used to build parts is

    made of two different materials, carbon and resin, whichis why it is called a composite. The long strings of carbon

    fibre resolutely resist bending and give the material its

    stiffness, and the resin acts as the glue that holds them

    together.

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    3. Flexibility:

    A carbon fibre part is formed by laying the material in a mould to

    give it its shape and is cured at high temperatures. Between parts

    of the same size, aluminium parts are more flexible than carbonfibre parts. We may experience a smoother operation with more

    shock absorption in aluminium.

    4. Braking :

    Aluminium wheels provide a more powerful braking surface,

    especially in wet, muddy conditions and on long descents. Some

    carbon fibre wheels will have aluminium braking surfaces.Sincea carbon fibre brake trackdoesnt dissipate heat as effectively as

    an aluminium brake track, the heat generated by braking builds

    up in the wheel and reduces stopping power.

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    5. Price :

    Aluminium parts are more affordable than carbonfibre parts. On average, aluminum parts costabout one-third to one-half of what carbon fibreparts cost

    6. Shaping:A carbon fibre part is formed by laying thematerial in a mould to give it its shape and iscured at high temperatures. Shaping the materialwith a mould, rather than welding tubes together,allows a manufacturer to develop componentswith clean aerodynamic shapes that areunattainable with metals

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    Manufacturing process of carbon fibre parts

    The four basic steps in the process ofmanufacturing a carbon fibre parts are:

    Mold design. Fabricating the mold.

    Laying of the Carbon fibre in the mold.

    Finishing of the part.

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    Step1Mold Design:

    The first step in the process is to design a moldthat can be used in a repeatable process. In orderto design the mold, we must first determine all ofthe specifications for the part that is to beproduced. Using the part specifications, the moldspecifications are determined. Thesespecifications must also account for all of the

    forces needed to successfully press the part. Fromthe mold specifications, a detailed AutoCADdrawing of the mold is created.

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    Step 2Fabricating the Mold

    After the drawing is completed, a mold can then befabricated. In order to make the mold, proper

    materials must be chosen to minimize cost and time.

    Once these materials have been chosen and

    obtained, then using the specifications and drawings

    of the mold, computer code must be written. This

    code can then be used in the final step, which is

    machining the mold. Since the machining processcould be very expensive, great care must be taken to

    prepare and test the tools. CNC lathe is the best

    machine for fabricating the mold.

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    Step3Initial Pressing of the part:

    Next, the parts may be cast. To cast the parts, themold must be properly set up. Then the fibre is tobe laid up within the mold. The fibre is thenpressed under certain temperature and pressureand is allowed for a certain time to cure. This isthe first step in the process of producing afinished working part. The mold must be coated

    so that the part does not adhere to the mold. Thenext problem is to lay-up the fibres in such amanner as to minimize the seams and maximizethe strength of the fibres.

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    Step4Finishing Process of the part

    After the parts have been pressed, the final

    step can be executed. The final step is

    finishing and assembling the part and its

    components. Any excess material that may

    have flowed out during pressing is trimmed.

    Then the separate pieces of the parts are

    assembled so the holes for any necessary boltsor other attachments may be drilled

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    ADVANTAGES:

    .

    The carbon-fiber composites can reduce a car's

    weight by up to 60 percent. Reducing a vehicle'sweight will increase fuel economy corresponding tothe weight being shed.

    Carbon fiber also benefits race car drivers, as the

    weight of a vehicle affects the acceleration andoverall speed of the car.

    Carbon fiber parts are 40-60% lighter than the alloy/metal parts.

    Lowers rotational inertia resulting in quick andresponsive steering i.e. less driver fatigue.

    Carbon fiber used in carbon fiber parts is free fromcorrosion.

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    The low weight but high stiffness of carbon fiberrims produces very light weight rim to wheelratio, significantly reducing the moment of inertia

    and unsprung mass. High strength to weight ratio is obtained.

    Very low co-efficient of thermal expansion.

    Improved acceleration. Greater fuel economy.

    Carbon fiber is stiffer than steel, and five timesstronger.

    Carbon fiber can also have a higher energy-absorption rate than steel and increases safetyduring collision.

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    DISADVANTAGES:

    Very expensive

    When we exceed tensile forces, the strength of the part fails.

    Recycling process is complicated and tedious.

    Recycled carbon fibre will be too weak, hence cannot be

    used in vehicle resulting in more wastage.

    Dents and cracks cannot be corrected like al parts.

    Poor resistance to abrasion and shocks.

    In case of carbon fibre wheels heat dissipation is low

    compared to al alloy wheel, hence poor braking in carbonfibre wheel.

    The main disadvantage of this carbon fibre in case of wheel

    is braking in wet conditions is dangerous.

    Carbon fiber is an electric conductor

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    Conclusion

    Adaptation of carbon fibre parts in a vehicle is still a

    budding technology, its used only in high end sportscars and bikes. Installment of carbon fibre parts is avery costly upgrade. Carbon fibre products becomescheaper in price and the technology can be applied in

    low end cars and bikes. This will increase the lifeand durability of the vehicles, hence increasing theirefficiency, mileage and other performancecharacteristics. There is lot of applications of carbonfiber in automobile sector which has resulted in lotof changes. However, if maximum aerodynamicadvantage with minimum weight is your goal, then afull carbon fibre products will likely be the betterchoice

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    Appendix-1

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    REFERENCES:

    www.wikepedia.org

    www.carbonfibergear.com www.ezinarticle.com

    www.ehow.com

    www.hiperwheel.com

    www.bikeradar.com

    Thesis paper of:

    Department of vehicle engineeringRoyal Institute of Technology. Stockholm, Sweden.

    Ford motor research

    Michigan

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    THANK YOU