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A composite material is a material system
composed of two or more macro constituents
that differ in shape and chemical compositionand which are insoluble in each other. The
history of composite materials dates back to
early 20th century. In 1940, fiber glass was first
used to reinforce epoxy.
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Hand Laminating with prepreg
Cutting Master Patterns
Patterns prepared for Moulding
Composite curing assembly
Chasis assembly
Flow chart of the fabrication process
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• Stacking of oriented layers of oriented prepreg
• Parameters that need to consider ply thickness, fibre type, ply
orientation and matrix materials and plies of the F1 team
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• Full needed size pattern are cut accordingly
based on setting of CAD system.
• The body are cut used 5 axis CNC millingmachine.
• Patterns are cut from a tooling block
material(generally contain solid epoxy resin
containing glass micro spheres)
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After MouldBefore Mould
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• Curing using the technique of internal pressure bag
• Pressure bag applying vacuum
• Additional pressure applied through elastomer bag
• The bag open to autoclave glass ensuring isostatic pressure applied to mould
parts
• Curing take place 7 bar pressure for 1-2 hours
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Manufacturing carbon fiber can have serious environmental ramifications
and pose immediate danger to humans.
HCN & NH3
Immediately
dangerous to
human health insmall quantities.
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Characteristics of materials
Super light weight
Super Strong
Super Stiff
Easily moulded into different shape
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Mechanical properties
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Example of usage
This carbon fibre safety cell is virtually indestructible and plays a key role in
the safety of Formula 1.
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References • Lin Liao, Journal of Advanced Materials, 1998, 30(4), 3-40.
• G.Pritchard, Reinforced Plastics Durability, Woodhead, 1999.
• Sehanobish, K, A Vision for Carbon Fiber Composites (CFC) inAutomotive, 2009,9th Annual SPE ACCE Keynote Presentations,(2009)
• Song,Y., Youn,J., Gutowski,T., Life cycle energy analysis of fiber-
reinforced composites. Composites, Part A 40 (2009) p. 1257
• Verpoest I, Thanh TC, Lomov S (2005) The TECABS Project:Development of Manufacturing, Simulation and DesignTechnologies for a Carbon Fibre Composite Car. Proceedings of the9th Japan International SAMPE Symposium, 56 –61.
• G. Savage, Composite material technology in formula 1 racingcar(2008)
• http://www.f1scarlet.com/f1_beginners.html#construction
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