Material and Bonding Conditions Optimization of Monocoque Inserts Based on Formula Student Electric China

Abstract

<div class="section abstract"><div class="htmlview paragraph">In the Formula Student Electric China (FSEC), the body structure is generally divided into two types, truss steel tube body and carbon fiber load-bearing body (monocoque). The monocoque is loved by Formula Student teams around the world because it has a higher stiffness and lighter weight than the truss steel tube body. With the widespread application of monocoque, it also brings more problems. Due to the use of the monocoque, the connection between each component and the body was changed from the welding of the original truss steel pipe frame to a bolted connection. However, the bolted connection will provide a large preload force to the monocoque, resulting in the monocoque easily crushed in the local, so it is necessary to pre-bury an enhanced part in the monocoque to ensure the connection strength, that is, the embedded part. At present, aluminum plug-ins after topological hollow processing are being used. Although the weight is reduced a lot, the assembly cross-sectional area is reduced, resulting in the inserts are easy to loosen, the connection is unstable, and even the lifting ears may be loose under severe working conditions, so that the vehicle is in an extremely unsafe state. It is necessary to optimize the material and bonding conditions of the inserts. In this paper, two engineering plastics, PPS and PPS with 30% glass fiber (PPS30), were selected and the bonding conditions were optimized in terms of several variables. The results show that the bonding strength is improved by the use of PPS30 and the optimization of the bonding conditions.</div></div>