Browse Topic: Unitized bodies and monocoque

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New Manufacturing Process for Monocoque ComponentsTBMG-3568012/1/2019
Rhodes Interform (Wakefield, West Yorkshire, England) has developed a new process that enables large monocoque components, particularly those produced by super plastic forming (SPF) from very thin material, to more accurately retain their shape on cooling.
AFP Monocoque Composite Tailboom Full Scale Fatigue TestingF-0070-2014-96385/20/2014
This paper describes two phases of full scale testing performed on a Bell Helicopter Textron Canada Limited (BHTCL) composite monocoque tailboom manufactured using Automated Fiber Placement (AFP). This technical demonstrator tailboom was designed for use on a Bell 407 model as part of a collaboration program with Bombardier Inc., Composite Atlantic Ltd. and the National Research Council Canada (NRC). The tailboom cone consisted of a skin made from an AFP layup of carbon epoxy fiber tape combined to a hand layup made from fabric. The skin is then bonded to six hand layup frames. The fatigue test objectives were to validate the component to flaw tolerant safe life requirements and establish damage tolerance to light and medium caliber ballistic impacts. The test article, containing embedded flaws, impact damages, and representative repairs, was subjected to a full four lifetime fatigue test at NRC. All testing during this phase was conducted at 250 °F 'hot-dry' conditions to simulate operating temperatures seen in service. The test article successfully sustained four lifetimes of fatigue testing, followed by residual strength testing to both limit and ultimate loads. In the second phase of the full scale testing, the article was subjected to six ballistic impacts with deadweights replicating a critical load condition in the field, interspersed with short 'go-home' fatigue cycling in the laboratory. Regular inspections and near-real-time data analyses were performed throughout testing. No permanent deformation, new damage or existing damage growth was sustained by the tested composite components during the fatigue tests, subsequent residual strength tests, or fatigue loads following ballistic impact, thereby proving the flaw and damage tolerance capability of the structure.
Beltempo, C., Rogers, John, Rutledge, Robert., Colle, Alain, Lapalme, Maxime, Drouin, Pierre
Design, Analysis, and Simulation of an Automotive Carbon Fiber Monocoque Chassis2014-01-10524/1/2014
While many composite monocoque and semi-monocoque chassis have been built there is very little open literature on how to design one. This paper considers a variety of issues related to composite monocoque design of an automotive chassis with particular emphasis on designing a Formula SAE or other race car monocoque chassis. The main deformation modes and loads considered are longitudinal torsion, local bending around mounting points, and vertical bending. The paper first considers the design of elements of an isotropic material monocoque that has satisfactory torsional, hardpoint, and vertical bending stiffness. The isotropic analysis is used to gain insight and acquire knowledge about the behavior of shells and monocoque structures when subjected to a vehicle's applied loads. The isotropic modeling is then used to set initial design targets for a full anisotropic composite analysis. The flexibility in composite layout and core design coupled with the superior material properties of carbon fiber composites is used to design and move toward an optimized monocoque composite design and layup to obtain satisfactory torsional, hardpoint and bending stiffnesses with minimal weight. Finally, some fatigue analysis considerations are outlined with emphasis on the endurance limit of the monocoque for a specific life span. The methods presented in this paper should be helpful in designing a monocoque structure chassis for FSAE race car or other applications.
Wu, Jingsi, Agyeman Badu, Owusu, Tai, Yonchen, George, Albert R.
Benefits and Methodology for Dimensioning a Vehicle Using a 3D Scanner for Accident Reconstruction Purposes2012-01-06174/16/2012
In the field of accident reconstruction, it is often important to measure the deformation of a vehicle (i.e. automobile, truck, motorcycle, etc.) after a crash has occurred. This data can be used for many purposes including energy calculations for speed loss, measuring roof or other structural deformation, analyzing seat or seat belt component positions, frame or unitized body structure deformation, and for estimating the actual post crash condition of a vehicle prior to the damage inflicted by the cutting and spreading tools used by emergency personnel. Traditionally, vehicle damage was measured using plumb bobs and tape measures or laser transits. However, these methods are not only time consuming but they also require a significant amount of upfront analysis to determine which points on the vehicle to measure at the inspection. In recent years, newer methods such as photogrammetry software and three dimensional scanners have come into play. Companies like FARO, Leica, Riegl, Trimble and Surphaser have developed these three dimensional laser scanners which can be used to efficiently document vehicle damage with millions of data points. The laser scanner equipment is simple to setup, collects data quickly and is accurate to a few millimeters. This paper describes the three dimensional scanning equipment and outlines a methodology of how to set it up at the vehicle inspection, how to process the voluminous data generated by the scanner, and then several case studies are presented showing how the data can be used in reconstructing crashes. The FARO Photon 80 scanner is used in examples.
Tandy, Donald F., Coleman, Clay, Colborn, Jason, Hoover, Todd, Bae, Jung
Comparison Between Finite Elements Model and Experimental Results for Static Stiffness and Normal Vibration Modes on a Unibody Vehicle2004-01-335111/16/2004
It is a well-know fact that cost and time-to-market constraints have gained an ever-increasing importance in the recent years in the global automotive industry. Either due to economic problems in emerging markets or to the presence of strong competition is US and Europe, automakers strive, using different strategies, to find ways of satisfying these constraints. One of the most promising tools to assist in reducing both development cost and time is CAE (Computer Aided Engineering) or Virtual Prototyping which, by using numerical models of components, systems and/or vehicles, is capable of assessing their behavior in areas such as noise, vibration and harshness (NVH), durability, impact safety and vehicle dynamics. A very important question that is frequently faced by CAE development teams is related to how well the numerical results match those that will be obtained when the vehicle is actually built. This work shows a study carried out for the new Ford Fiesta, focused on NVH behavior. Results from both numerical models and actual physical testing for static stiffness (bending and torsion) and normal vibration modes are compared, allowing development engineers to have a clear picture of what is the degree of accuracy they can expect to current CAE techniques in the body NVH area.
Magalhães, Marcelo, Ferraz, Fábio, Agostinho, Alexandre
Monocoque Tank Analysis Spreadsheet System, Version 2.0TBMG-67402/1/2000
The Monocoque Tank Analysis Spreadsheet System (MONTASS) computer program is an integrated software system that incorporates Microsoft Excel worksheet software and Visual BASIC software. MONTASS was developed to enable rapid analysis and preliminary design of structural domes and truncated sections of cones.
Engineering A New Generation of Small Cars: Dodge Aspen and Plymouth Volare7511861/1/1975
Chrysler Corporation used a mini-systems approach in the design and manufacture of a new generation of small cars, not merely new models. These cars are the Plymouth Volare and Dodge Aspen. A new generation of cars is defined as a full line of vehicles - 2-door coupe, 4-door sedan, and 4-door station wagon - which offer customers new values for this size car, especially in the areas of rideability, handling, fuel efficiency, visibility, roominess, comfort, quietness and amenities. In addition, a new generation of cars means an adaptable and cost-efficient product that, because of its design and manufacturing flexibility, can serve as a model for the resizing and redesign of the corporation's complete line of cars in the last half of this decade. The enormous complexities involved in this development, including intensive simplification and standardization programs, can best be guided and managed as system, rather than by analyzing the many pieces of the task and attempting to optimize the individual elements. This approach is the only presently known way of stopping costs from escalating. Engineers by training, if not also by instinct, understand the necessity for a systems approach better than other professionals and are in position to assume a leadership role in establishing and constantly refining a systems approach that is corporate-wide and is effective in coping with the unpredictable worldwide market conditions we face in the years ahead.
Loofbourrow, Alan G.
Application of Finite Element Method to Predict Static Response of Automotive Body Structures7102632/1/1971
Applications of the finite element method for analysis of partial and complete body structures are described. Ford Motor Co.'s version of the Structural Analysis and Matrix Interpretive System (SAMIS) computer program provides the capability for a static analysis of structures with over 10,000 degrees of freedom. Special modeling techniques for spot welded structural components have been investigated. Also, methods for quick input data development and effective visual displays of output data are discussed.
Petersen, Willy
Construction and Strength of Convertible Bodies6101291/1/1961
Schwarze, K.
BASIC PASSENGER VEHICLE CONSTRUCTION OR UNITIZED VERSUS BODY/FRAME6105401/1/1961
FREY, D. N., RICHARDS, J. W.
SUSPENSION DESIGN FOR SINGLE UNIT CONSTRUCTION6003621/1/1960
KISHLINE, F. R., LAWLER, T. M.
THE UNITIZED APPROACH TO LOW CARS5803591/1/1958
JOHNSON, H. W.
The Continental Mark II —A Design Story—5700271/1/1957
STYLING the Continental Mark II with a very low silhouette without sacrificing leg room, seating comfort, and driver visibility was accomplished by using a specially designed frame and a 3-joint driveline. These two features are the basic engineering innovations which make possible the Continental's distinctive classic styling. As a result of this structural analysis, Ford has produced an automobile that, according to the author, has technical advancements that are of value to the consumer.
Copp, H. F.
UNITIZED BODY DESIGN - Bodies - With or Without Chassis Frames5400401/1/1954
Nagler, L. H.
HUDSON MONO-BILT CONSTRUCTION5400391/1/1954
BALD, MILTON S.
Technical Highlights Of Postwar Automobiles4900511/1/1949
WOLF, AUSTIN M.
THE FRAMELESS CAR4501321/1/1945
Ulrich, Theodore
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