Browse Publications Technical Papers 2002-01-1121
2002-03-04

Development of a Carbon Fibre Composite Ultra Lightweight Vehicle Structure for the Aero-Stable Carbon Car - Fastframes 2002-01-1121

The Aero-stable Carbon Car (ASCC) was the first full vehicle structure project of the UK government DTI program ‘Foresight Vehicle’. The project investigated the limitations to maximising fuel economy in a lightweight car manufactured in carbon fibre composite (CFC). The EPSRC Integrated Manufacturing initiative / industry funded project FastFrames is developing design understanding and materials / manufacturing technology for lightweight vehicle structure and components.
Current lightweight composite vehicles such as racing cars use a monocoque, stressed skin design approach for both weight and manufacturing cost reasons. For passenger cars with large ‘cut-out’ areas for access, the approach of a space-frame supporting fairing panels offers the opportunity for a more efficient structure. It also offers the potential to incorporate localised loads from suspension, engine and door mounting, seats and seat belts more easily than for a thin section stressed skin approach. Manufacturing the space frame using carbon fibre composite materials provides a very lightweight structure. With current manufacturing approaches, the problems of labour cost for material lay up and bonding sections preclude the use of the framework approach. For this project a novel design and materials approach was conceived and developed. The approach uses a novel form of textile preform laminated to form a single piece integrated frame structure. Lightweight panels are bonded to the assembled frame after systems fitting. The approach should result in a total body weight of 125 kg, which compares to around 320 kg for a similar size steel car.

SAE MOBILUS

Subscribers can view annotate, and download all of SAE's content. Learn More »

Access SAE MOBILUS »

Members save up to 18% off list price.
Login to see discount.
Special Offer: Download multiple Technical Papers each year? TechSelect is a cost-effective subscription option to select and download 12-100 full-text Technical Papers per year. Find more information here.
We also recommend:
JOURNAL ARTICLE

Predicting Impact Damage, Residual Strength and Crashworthiness of Composite Structures

2016-01-0497

View Details

TECHNICAL PAPER

Noise Reduction at Source for a Vehicle Using Free Layer Damper

2011-26-0067

View Details

TECHNICAL PAPER

Designing for Insurability:Best Practices to Achieve Lower Vehicle Repair Costs

2004-01-1774

View Details

X