Riassunto analitico
This thesis, completed at the culmination of an internship at Bold Valuable Technology, focuses on the design of a support structure for the fuel tank of a sports car using advanced composite materials. The primary goal is to develop an optimal design for the component, with two distinct manufacturing processes - Prepregs Lay-up and Carbon Fiber Sheet Moulding Compound (CFSMC) - serving as the pathways to achieve this design.
The first manufacturing process, Prepregs Lay-up, results in a component with orthotropic behaviour, while the CFSMC process produces a component with isotropic properties. The designs will undergo initial hand calculations followed by Finite Element Analysis (FEA) to evaluate structural performance. Additional considerations include cost analysis, tooling requirements, and manufacturability, with the aim of determining the most suitable solution for high-performance automotive applications.
The thesis is structured into four chapters. Chapter 1 introduces the key concepts of composite materials, which underpin the initial sizing of the component. Chapter 2 defines the design goals, explores market trends, and provides a detailed description of the two manufacturing processes. Chapter 3 outlines the embodiment design, including sizing, FEA, redesign, validation, tooling, cost analysis, and a final comparison of the two manufacturing solutions. Chapter 4 concludes with a review of the results and offers a recommendation for the optimal design solution.
This study provides insights into the trade-offs between different manufacturing approaches for composite components in sports car engineering, balancing performance, cost, and production feasibility.
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