Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures

Journal article


Khan, Laraib Alam, Mahmood, Ali Hasan, Hassan, Bilal, Sharif, Tahir, Khushnod, Shahaab and Khan, Zaffar 2013. Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures. Polymer Composites. https://doi.org/10.1002/pc.22638
AuthorsKhan, Laraib Alam, Mahmood, Ali Hasan, Hassan, Bilal, Sharif, Tahir, Khushnod, Shahaab and Khan, Zaffar
Abstract

The advanced composite materials are increasingly being used in the automotives for their ultralight physical properties and super strong mechanical properties. This research examines the cost-effective single-step liquid resin infusion manufacturing process for developing all composite car body as the generally used sheet molding compound manufacturing process is highly capital intensive. Three different scaled down models of the Eco car were developed focusing on minimal weight and air drag coupled with aesthetics. Structural design and analysis was carried out using the Pro/E and Ansys tools. The Pro-E model was scaled up to generate computer-aided drafting drawings for tool development. Different stations were marked on the model and sliced virtually for development of pattern. Moreover, the mold was manufactured from carbon and glass/polyester composites for prototype manufacturing of the car body. This involved manual placement of desired number of carbon layers as preform on female side of the mold. The vacuum sucked the resin through a number of carefully selected entry ports which ensured effective resin distribution and impregnation. Polycarbonate wind shield was thermoformed in the convection oven according to streamlined geometry of car body and hinged. The car body was integrated with the compatible floor panels and accessories. The crumble zone shock absorber in the bumper was manufactured using successive layers of nomax honeycomb and polyvinyl chloride rigid foam to dampen the accidental shock. The car performed remarkably well in the Eco marathon race held at Malaysia, 35:97–104, 2014. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineers

KeywordsComposites; Sandwich structure; Modelling; Composite car body
Year2013
JournalPolymer Composites
PublisherWiley
ISSN02728397
Digital Object Identifier (DOI)https://doi.org/10.1002/pc.22638
Web address (URL)http://hdl.handle.net/10545/621208
hdl:10545/621208
Publication dates23 Aug 2013
Publication process dates
Deposited21 Dec 2016, 09:53
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ContributorsNED University of Engineering and Technology, Centre for Emerging Sciences, Engineering and Technology (CESET), GIK Institute for Science and Technology, Glyndwr University, University of Engineering and Technology, Department of Physics; Centre for Emerging Sciences; Engineering and Technology (CESET); Islamabad Pakistan, Department of Textile Engineering; NED University of Engineering & Technology; Karachi Pakistan, Department of Mechanical Engineering; GIK Institute for Science and Technology; Toppi Pakistan, Advanced Composite Training and Development Centre; Glyndwr University; Unit 5, Hawarden Industrial Park Deeside Flintshire, Department of Mechanical Engineering; Faculty of Aeronautical and Mechanical Engineering; Advanced Materials and Smart Structures Laboratory; University of Engineering and Technology; Taxila Pakistan and Department of Physics; Centre for Emerging Sciences; Engineering and Technology (CESET); Islamabad Pakistan
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