8/6/2019 FYP Abstract
1/3
Acad Year
10/11
PROJECT NO
B498
DESIGN AND MANUFACTURING OF THE
COMPOSITE MONOCOQUE INTERNAL STRUCTURES
AND MECHANICAL COMPONENTS OF
THE NTU WORLD SOLAR CHALLENGE CAR
DESIGNANDMAN
UFACTURINGOFCOMPOSI
TEMONOCOQUEINTERNALSTRUCTURES
ANDMECHANICALCOMPONENTSOFTHE
NTUWORLDSOLARCHAL
LENGECAR
Tan Sia Nguan Eugene
SCHOOL OF MECHANICAL AND AEROSPACE ENGINEERING
NANYANG TECHNOLOGICAL UNIVERSITY
Year 2010/2011
8/6/2019 FYP Abstract
2/3
DESIGN AND MANUFACTURING OF THE COMPOSITE MONOCOQUE
INTERNAL STRUCTURES AND MECHANICAL COMPONENTS
OF THE NTU WORLD SOLAR CHALLENGE CAR
SUBMITTED
BY
TAN SIA NGUAN EUGENE
SCHOOL OF MECHANICAL AND AEROSPACE ENGINEERING
A final year project reportpresented to
Nanyang Technological University
in partial fulfilment of the
requirements for the
Degree of Bachelor of Engineering (Mechanical Engineering)
Nanyang Technological University
Year 2010/2011
8/6/2019 FYP Abstract
3/3
1
Abstract
In this report, the intricate process of the design and
development stages of a
carbon-fiber composite monocoque chassis of the NTU solar car
has been
emphasized in detail. By building on the success of the previous
car (Nanyang
Venture II), the new and improved car (Nanyang Venture V) has
been designed to
participate in the World Solar Challenge 2011, a solar car race
held in Australia that
spans across a distance of 3021 km from Darwin to Adelaide.
As the design and development of a carbon-fiber composite
monocoque chassis
involved multiple intricate stages, the mechanical systems of
the solar was designed
and analyzed first before integrating it to the monocoque
chassis. Mechanical
systems consisting of the steering systems, suspension systems
and braking systems
were designed and optimized based on their respective design
intentions and
constraints. Figures and references were occasionally used to
aid the explanation of
the concepts behind the complexities of the mechanical
systems.
During the development stages, an aluminium tubular frame was
designed and
fabricated to test the design integrity of these mechanical
systems dynamically via
braking and endurance tests. Results from the tests were then
used as guidelines to
design the structural elements of the monocoque chassis. Due to
complexities of
carbon-fiber composites, simulations and essential calculations
were also performed
to design the lightest and stiffest composite chassis.
Advance technologies and methodologies regarding the
incorporation of the
mechanical systems and the composite structures were also
explored to prove the
concept of a full carbon-fiber monocoque car. In conclusion,
suggestions regarding
future improvements and technological developments were
discussed to guide the
next generation of students that will be working on future solar
car projects.
