Carbon Fibre Steering Wheel Design, Analysis and

Manufacture

Group Members: Amit Prem

Clement Ooi Ciprian Chivoiu

Carbon Fibre Steering Wheel: Design to Manufacture

• Steering wheel was designed for the University Subaru and 206 race cars.

• Concept Design and Stress analysis were undertaken using CAD and CAE software's.

• Displacement load and Torsion loads Applied at 6 and 12 O clock

Steering Wheel design & drawing

Hyperlaminate Analysis

Carbon Fibre Steering Wheel: Mould Design and Ply layup

Mould designs-Catia V5

Ply Layup sequence

• Carbon pre-preg 8020 200gsm 2*2 twill

• Rim thickness 1.5mm with M250 mould insert, cured separately and bonded

• Steering Centre and spokes 4mm thickness

Carbon Fibre Steering Wheel: M250 mould- CNC machined

• Paper templates were created to cut the Carbon fibre

• Ply layup was carried out as per the sequence earlier.

• The Rim was manufactured as two Halves and then post-cured to form a single component.

• The rim was then integrated into the main mould as per the above diagram.

• Cured at 110 degrees, vacuum bagged under heat lamps and for 2 and half hours.

Carbon Fibre Steering Wheel: Ply Layup and Curing

Carbon Fibre Steering Wheel: Finished Product

• 50.56% of weight savings was achieved by using Carbon fibre.

• The internal reinforcement provided additional stiffness to the steering rim.

• The steering wheel was a perfect fit onto the Race cars.

• The steering wheel went through all the stages from concept to a finished product.