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Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann...
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Transcript of Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann...
![Page 1: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/1.jpg)
Creating a Future for Engineers
Formula Student Germany
Wet laminated CFRP monocoque
Manuel Baumann amz.ethz.ch
![Page 2: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/2.jpg)
Creating a Future for Engineers
Introduction
![Page 3: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/3.jpg)
Creating a Future for Engineers
Mold manufacturing
Part manufacturing
Additions
Potential
Bill of Material
Timeline
Index
![Page 4: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/4.jpg)
Creating a Future for Engineers
Positive molds
Laminated negativ molds
Wet laminated monocoque
Bonded halves
Mold manufacturing – Concept
![Page 5: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/5.jpg)
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
![Page 6: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/6.jpg)
Creating a Future for Engineers
Mold manufacturing – Positive molds Bonding
![Page 7: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/7.jpg)
Creating a Future for Engineers
Mold manufacturing – Positive molds Milling
![Page 8: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/8.jpg)
Creating a Future for Engineers
Mold manufacturing – Positive molds Sanding
![Page 9: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/9.jpg)
Creating a Future for Engineers
Mold manufacturing – Positive molds Priming
![Page 10: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/10.jpg)
Creating a Future for Engineers
Mold manufacturing – Positive molds Bolts for insert positioning
Internal thread
![Page 11: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/11.jpg)
Creating a Future for Engineers
Material choice: CFRP
Alternative material: GFK
Mold manufacturing – Negative molds
![Page 12: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/12.jpg)
Creating a Future for Engineers
Formenharz P
Mold manufacturing – Negative molds
![Page 13: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/13.jpg)
Creating a Future for Engineers
Formenharz P
Connection layer:
Epoxy
Fibreglas
Flocs
Thixotropiermittel
Mold manufacturing – Negative molds
![Page 14: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/14.jpg)
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
600 gr/m²
Mold manufacturing – Negative molds
![Page 15: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/15.jpg)
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Mold manufacturing – Negative molds
![Page 16: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/16.jpg)
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Demoldi
Mold manufacturing – Negative molds
![Page 17: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/17.jpg)
Creating a Future for Engineers
Formenharz P
Connection Layer
6 Layers Carbon Fibre
Vacuum
Demold
Finished mold
Mold manufacturing – Negative molds
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Creating a Future for Engineers
Core material:
Divinycell HP 60 foam
Insert material
Carbon and wood
Part Manufacturing – Material choice
![Page 19: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/19.jpg)
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Part manufacturing – Monocoque halves
![Page 20: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/20.jpg)
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Vacuum bonding
Sanding
Part manufacturing – Monocoque halves
![Page 21: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/21.jpg)
Creating a Future for Engineers
Mold release agent
Frecote
Part manufacturing – Monocoque halves
![Page 22: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/22.jpg)
Creating a Future for Engineers
Mold release agent
Frecote
Resin: Hexion L 235
Hardener L236
Microballons for filling the gaps
Part manufacturing – Monocoque halves
![Page 23: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/23.jpg)
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
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Creating a Future for Engineers
Bonding
the halves
Part manufacturing – Joining upper and lower halves
![Page 25: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/25.jpg)
Creating a Future for Engineers
Roll hoop
Part manufacturing – Additional structural parts
![Page 26: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/26.jpg)
Creating a Future for Engineers
Roll hoop
Rib
Part manufacturing – Additional structural parts
![Page 27: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/27.jpg)
Creating a Future for Engineers
Weight: 21kg (without rollhoops)
Part manufacturing – Result
![Page 28: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/28.jpg)
Creating a Future for Engineers
Painting
Degreasing
Primer
Sanding
White color
Sanding
White color
Clear varnish
4kg
Part manufacturing – Additional structural parts
![Page 29: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/29.jpg)
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
![Page 30: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/30.jpg)
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
![Page 31: Creating a Future for Engineers Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch.](https://reader037.fdocuments.in/reader037/viewer/2022103022/56649cea5503460f949b4b7e/html5/thumbnails/31.jpg)
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
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Creating a Future for Engineers
05. – 09. August 2009
See you at Hockenheim