Optimised ultrafast lightweight design and finite element modelling of a CFRP monocoque electric car chassis
by Evangelos Ch. Tsirogiannis; Georgios E. Stavroulakis; Sofoklis S. Makridis
International Journal of Electric and Hybrid Vehicles (IJEHV), Vol. 11, No. 3, 2019

Abstract: A breakthrough in the process method has been developed by combined considerations in the demands of "Shell Eco Marathon" using finite element modelling (FEM). Ultrafast calculations have revealed novel chassis development. The most critical factors in designing the new chassis are the reduction of the weight, the improvement of strength and stiffness, the reduction of material and the manufacturing cost. The simple structural surfaces (SSS) method was used for an electric car so as the type of loading conditions which are applied to the chassis structure to be predicted. Afterwards, a new design approach for a lightweight carbon-fibre reinforced polymer (CFRP) monocoque chassis is proposed which conforms to structural, ergonomic, safety and aesthetic requirements. The SSS method in conjunction with the creation of the chassis load calculator (CLC) model and both the specialised and integrated methodology of the processing procedure through FEM, have attained the overcoming of the time consuming conceptual design process.

Online publication date: Tue, 30-Jul-2019

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