Highlights

Design, analysis, testing, and manufacturing of two composite monocoque chassis of a Formula Student racecar.

• Mathematical modeling of composite sandwich panels
• Structural optimization using custom MATLAB codes
• Finite element analysis of composite structures
• Physical testing to validate calculations and simulations

ME 497 - Senior Capstone I, Fall 2017
ME 498 - Senior Capstone II, Winter 2018
ME 406 - Special Projects, Spring 2018

Background

Formula SAE and Formula Student are student-based competitions where universities around the world design, build, and race a formula-styled racecar.

The Team

Global Formula Racing (GFR) is one of the most competitive teams to enter Formula SAE and Formula Student events, with a long-standing history of podium placings at competitions around the world. The team is comprised of students from Oregon State University (US) and DHBW-Ravensburg (DE) who work collaboratively to create both a combustion (cCar) and electric (eCar) vehicle every year.

Monocoque Chassis

For nearly a decade GFR has used advanced composite materials to create one of the lightest monocoque chassis of any team.

Classical Laminate Theory

Calculated elastic properties of any laminate and sandwich panel.

Failure Analysis

Multi-mode failure analysis including core shear, microbuckling, core indentation, and facesheet wrinkling.

Exhaustive Search

Structural Simulation

Numerical characterization of the design of fiber-reinforced composite structures.

Developed simulation models in FEMAP with NX Nastran and ANSYS Mechanical APDL.

Physical Testing

Validated mathematical model and numerical simulations through physical testing using an Instron universal tester.

Tests include three-point-bend, quasi-static crush, dynamic impact, perimeter shear, and hardpoint pullout.

Data Analysis

Created MATLAB code to import raw test data, analyze results, and calculate mechanical properties of the test specimen.