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Formula Student Germany. Wet laminated CFRP monocoque. Manuel Baumann amz.ethz.ch. Introduction. Mold manufacturing Part manufacturing Additions Potential Bill of Material Timeline. Index. Positive molds Laminated negativ molds Wet laminated monocoque Bonded halves.
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Formula Student Germany Wet laminated CFRP monocoque Manuel Baumann amz.ethz.ch
Mold manufacturing Part manufacturing Additions Potential Bill of Material Timeline Index
Positive molds Laminated negativ molds Wet laminated monocoque Bonded halves Mold manufacturing – Concept
Mold manufacturing – Molding material Disadvantage MDF • Inhomogeneous density over thickness • Sensitive to humidity
Mold manufacturing – Positive molds • Bonding
Mold manufacturing – Positive molds • Milling
Mold manufacturing – Positive molds • Sanding
Mold manufacturing – Positive molds • Priming
Mold manufacturing – Positive molds • Bolts for insert positioning • Internal thread
Material choice: CFRP Alternative material: GFK Mold manufacturing – Negative molds
Formenharz P Mold manufacturing – Negative molds
Formenharz P Connection layer: Epoxy Fibreglas Flocs Thixotropiermittel Mold manufacturing – Negative molds
Formenharz P Connection layer 6 Layers carbon fibre 600 gr/m² Mold manufacturing – Negative molds
Formenharz P Connection layer 6 Layers carbon fibre Vacuum Mold manufacturing – Negative molds
Formenharz P Connection layer 6 Layers carbon fibre Vacuum Demoldi Mold manufacturing – Negative molds
Formenharz P Connection Layer 6 Layers Carbon Fibre Vacuum Demold Finished mold Mold manufacturing – Negative molds
Core material: Divinycell HP 60 foam Insert material Carbon and wood Part Manufacturing – Material choice
2 core layers of 5mm Heat bending Part manufacturing – Monocoque halves
2 core layers of 5mm Heat bending Vacuum bonding Sanding Part manufacturing – Monocoque halves
Mold release agent Frecote Part manufacturing – Monocoque halves
Mold release agent Frecote Resin: Hexion L 235 Hardener L236 Microballons for filling the gaps Part manufacturing – Monocoque halves
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
Bonding the halves Part manufacturing – Joining upper and lower halves
Roll hoop Part manufacturing – Additional structural parts
Roll hoop Rib Part manufacturing – Additional structural parts
Weight: 21kg (without rollhoops) Part manufacturing – Result
Painting Degreasing Primer Sanding White color Sanding White color Clear varnish 4kg Part manufacturing – Additional structural parts
Prepreg Monocoque: -Temperature resistant resin for negative molds -Same manufacturing process Advantage: Less weight, better surface, no painting needed Additions – Potential
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
See you at Hockenheim 05. – 09. August 2009