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Year 2010/2011
DESIGN AND MANUFACTURING OF THE COMPOSITE MONOCOQUE
INTERNAL STRUCTURES AND MECHANICAL COMPONENTS
OF THE NTU WORLD SOLAR CHALLENGE CAR
SUBMITTED
BY
Year 2010/2011
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.
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.