Research and structural optimization of lattice core based on monocoque of Formula Student racing car

Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types. In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Hypermesh simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments and circumferential shear experiments. Different from the previous lightweight work based a lot on experience, this project improves the lightweight level and strength of the whole vehicle from two more scientific aspects: modeling design and layup and core design. It is noteworthy that we will innovatively try the lattice core material, which has the characteristics of low relative density and high specific strength, and has complexity and designability, compared with the traditional aluminum honeycomb or the foam board, and has more room for optimization. And explore the possibility of using lattice sandwich in some areas, such as the bottom plate, side anti-collision area, etc., and even the whole monocoque.