Comprehensive Design Methodology of a Vehicle Monocoque: From Vehicle Dynamics to Manufacturing

Climate change has become a real problem in our world. Society is trying to contain it as much as possible, promoting more sustainable behaviors and limiting pollution. For the automotive industry, this leads to progressive electrification and reduction of tailpipe emissions and fuel consumption for conventional vehicles. In this framework, this paper presents the design of a vehicle to compete in the Urban Concept category of Shell Eco Marathon, a competition among universities that has the goal to release a vehicle with the lowest possible fuel consumption. This work describes the monocoque design phases of the vehicle JUNO. The complete design approach is described, through the analysis of the decisional workflow adopted to integrate every technical solution from the aerodynamic constraints to the structural ones passing from the vehicle dynamic requirements. The methodology adopted to size the monocoque is explained in depth through the analysis of the multi-step optimization performed by means of finite element models. Therefore, the load configuration and the design constraints are illustrated with the aim of mass optimization. Specifically, the rollover and the torsional stiffness test have been chosen as the most significative load cases in terms of structural integrity and performance respectively. Furthermore, the definition of the final monocoque geometry and stacking sequence is described together with the virtual results obtained. Finally, a brief explanation of the production process is presented, to complete all the project phases.