'HELIOS' the Sun God. The epitome of Energy. That is who we have decided to name our new prototype after. After much discussions (on both the name and the concept for the design!) these are some of our conclusions.
We plan to make the car chassis of foam composites. Foam can be polyurethane or aramid slabs. Honeycomb type mesh is also a very effective type of core in sandwich composites essentially used for weight reduction and providing optimum strength. Carbon fiber is also an important feature in these composites. Many types of carbon fiber weavings are available -unidirectional, plain weave, twill weave, harness satin weave with different densities of fibers (2k, 3k, etc). Deciding the type of fabric to be used is essential as it will prevent unnecessary weight addition and cost. Using unidirectional fabric layers or 4H harness Satin weave is a good option for the base of the chassis. Vibration of engine and its effects on the composite interface are to be analyzed. In the analysis, parameters like meshing, element attributes, material properties, vibration amplitudes, boundary conditions, etc are imperative to get right for reliable results.
Aerodynamic study of the car is essential to reduce drag force as it increases performance of the vehicle. More time we get to analyze the prototype, the better will be the car. Tear drop structures, covered wheel rims, etc are certain features implemented to reduce drag. During analysis mesh sizing and refining, size of control volume, mesh element shape, etc. are to be set appropriately. A prototype model analysis using a wind tunnel is also a great way to determine if software analysis is in good agreement. Manufacturing the shell is also a massive task given the tools constraint. Hence, sampling is essential to come up with a simple yet precise method to get desired results. Accuracy in the mold and surface finish of the shell are key factors in manufacturing. For weight reduction, type of resin and application of the same is important. Making a carbon fiber shell and chassis requires special equipment like an oven and vacuum bagging for maximum weight reduction and strength.
Stay tuned for more on the design and the technical specs. of the prototype.
Meanwhile feel free to visit our Facebook page http://www.facebook.com/teamecotitans
We plan to make the car chassis of foam composites. Foam can be polyurethane or aramid slabs. Honeycomb type mesh is also a very effective type of core in sandwich composites essentially used for weight reduction and providing optimum strength. Carbon fiber is also an important feature in these composites. Many types of carbon fiber weavings are available -unidirectional, plain weave, twill weave, harness satin weave with different densities of fibers (2k, 3k, etc). Deciding the type of fabric to be used is essential as it will prevent unnecessary weight addition and cost. Using unidirectional fabric layers or 4H harness Satin weave is a good option for the base of the chassis. Vibration of engine and its effects on the composite interface are to be analyzed. In the analysis, parameters like meshing, element attributes, material properties, vibration amplitudes, boundary conditions, etc are imperative to get right for reliable results.
Video Teaser of 'HELIOS
Stay tuned for more on the design and the technical specs. of the prototype.
Meanwhile feel free to visit our Facebook page http://www.facebook.com/teamecotitans
