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Author:Väisänen, Jaakko Tuomas
Title:Sizing of a composite vehicle frame
Komposiittirakenteisen ajoneuvon runkorakenteen mitoitus
Publication type:Master's thesis
Publication year:2012
Pages:79      Language:   eng
Department/School:Sovelletun mekaniikan laitos
Main subject:Lentotekniikka   (Kul-34)
Supervisor:Saarela, Olli
Instructor:Santamala, Harri
OEVS:
Electronic archive copy is available via Aalto Thesis Database.
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Location:P1 Ark Aalto  3988   | Archive
Keywords:bio composites
composite vehicle frame
ANSYS Composite PrepPost
biokomposiitti
komposiittirakenteinen
ajoneuvon runko
Abstract (eng): The purpose of this study is to analyse the composite frame of a city car for structural sizing purposes.
The aim of the thesis is to present design methods and analysis tools which are used for obtaining reliable simulation for the structural frame of Metropolia's eco-friendly City-Car.
Another aim is to present analysis methods for designing the joints between composite parts.
Finally, the frame is optimized, in respect of mass and carbon footprint.
The optimization method, process and results are reviewed at the end of the thesis.

The structure must be analysed beforehand to verify that it is capable of carrying specified loads.
Several analytical methods were reviewed but the requirements for the analysis dictate that the only possible way to analyse the complex composite frame is the numerical analysis method.
Also the joints are examined by the numerical analysis method.
The numerical method has some disadvantages and the behaviour of numerical analysis model needs to be evaluated to make sure that it behaves correctly.
The evaluation is done with simplified analytical computation methods.

The result of the study is that the design of fabric lay-up meets the design requirements.
It is discovered that also recyclable bio composites are possible to use for structural purposes with some cautions.
The conclusion is that the composite vehicle frame can be manufactured based on obtained fabric lay-up maps.

The produced knowledge will be utilized in a demonstration vehicle for testing and verification purposes.
The demonstration vehicle will be fully functional and drivable, and it will be introduced at 2014 Geneva Motor Show.
Abstract (fin): Työssä esitellään komposiittirakenteisen kaupunkiauton runkorakenteen mitoitukseen soveltuvia analyysimenetelmiä.
Tavoitteena on löytää suunnittelu- ja laskentamenetelmät, joita käytettiin rakennemitoituksessa Metropolia Ammattikorkeakoulun ympäristöystävällisen kaupunkiauton kantaviin runkorakenteisiin.
Lisäksi tavoitteena on esitellä runkorakenteessa käytettävien komposiittiosien välisten liitosten suunnittelu- ja laskentamenetelmät.
Tehokkaan lopputuloksen saavuttamiseksi runkorakenne optimoidaan massan suhteen.
Optimointimenetelmä ja -prosessi sekä optimoinnin tulokset esitellään myös lopussa.

Runkorakenne on analysoitava etukäteen, jotta voidaan olla vannoja rakenteen kestävyydestä, kun sitä kuormitetaan ajotilanteissa syntyvilla kuormilla.
Useita analyyttisia laskentamenetelmiä tarkasteltiin, mutta ainoa varteenotettava laskentamenetelmä kyseessä olevaan monimutkaiseen rakenteeseen on numeerinen laskentamenetelmä.
Myös liitokset analysoitiin numeerisella laskentamenetelmällä.
Numeerisissa laskentamenetelmissä on myös haittapuolia ja niiden toimivuus on varmistettava.
Mallin toimivuutta on varmistettu yksinkertaistetuilla analyyttisilla tarkasteluilla.

Työn tuloksena saavutettiin valituilla analyysimenetelmillä komposiittiosien ladontakokoonpano, joka täyttää suunnittelukriteerit.
Analyysin perusteella huomattiin, että biokomposiitteja on myös mahdollista hyödyntää jossain määrin kantavissa rakenneosissa.
Loppupäätelmä on, että ajoneuvon runkorakenne voidaan valmistaa analyysissa saavutetun ladontakartan perusteella.
Valmistettava demonstraatio ajoneuvo tullaan esittelemään Geneven autonäyttelyssä vuonna 2014.
ED:2012-10-01
INSSI record number: 45314
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