Abstract
Lately, numerous studies have been performed to design composite monocoque’s with high strength and low weight for various student-level racing contests. The objective of this paper is to develop an insightful methodology to design and developed a lightweight composite monocoque. The monocoque is designed to pass the mandatory static load tests laid down by the International Automobile Federation (FIA) Formula 3. These Formula 3 tests are considered the baseline of the desired structural integrity of the composite monocoque. The presented design technique emphasizes on a monocoque developed for Sports Car Club of America races. The three standard load tests performed on the monocoque are survival cell side test, fuel tank test and side intrusion test. A sandwich layup of bidirectional-woven carbon/epoxy prepreg and aluminum honeycomb is optimized for minimum weight while predicting the unknown properties of layup, and ensuring the monocoque does not experience failure. The approach intends to achieve minimum weight with high torsional rigidity and is capable of being used for the design and analysis of any kind of formula-type composite monocoque.
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