Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars

In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. In recent years, most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three-point bending tests, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This paper introduces adhesive failure factors into the simulation model, establishes a comprehensive simulation framework based on the bonding performance of GXA-120 toughened epoxy prepreg film, and validates it through actual three-point bending tests, aiming to improve the accuracy of laminate experimental simulations and thereby enhance the efficiency of laminate design for the teams.