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Document used to compile all the work is here:
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The approach for calculating adhesive strength involved hand calculations of simplified force models and simulations using Ansys Static Structural. A simplified force model involves creating a more simplified and worst case scenario. This was to be done because there exists multiple adhesive joints between the bonding of two components, each at different angles. This made it difficult to accurately calculate the force distribution using solely hand calculations. Simulations were used to get a better approximation of the expected force the adhesive would endure.
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Adhesives are stronger in shear than in tension, therefo. Figure 1 shows how the bonding in MS XIV can become more complex when more adhesive joints are involved which brings the need for simulations.
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Figure 1: Images to show complex bonding in MS XIV compared to more basic bonding scenarios
should probably divide this into the scenarios looked at: 2G bump and Crash Scenarios
Make tips for creating simplified model; worst case scenario
go from hand calc approach to simulation set up (features used)
display hand calc results and sim results in an organized table + should show formulas used as equations
lastly talk about design safety factor for adhesives -
There are two main loading scenarios that the vehicle should be designed towards:
2G bump (ASC2020, Appendix F, F.2)
This basically features a loading scenario consisting of twice the weight of the car’s mass
Vehicle collision scenarios. (ASC2020, Appendix F, F.3)
There are a total of 12 loading scenarios featuring a 5G impact at different directions and angles
Not all carbon fibre parts are expected to be structural therefore selected crash scenarios are placed at higher priority for analysis
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Figure 2: Vehicle Collision Scenarios (ASC 2020, Appendix F, F.3.3)
Bonding scenarios in MS XIV that were considered in this analysis
The bonding between the Chassis and the Bottom Panel must be structural.
This structure contributes to the foundation of the car.
The bonding between the bulkheads and the Chassis.
Bulkheads A and C cover the front and back of the Chassis.
They are used for cover and may be used for mounting.
They are not designed to be structural; the Chassis is primarily responsible for withstanding vehicle impacts
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Figure 3: Shows the bonding area and force diagram for the bonding between the Chassis and Bottom Panel. Bulkhead A can be seen at the front (to the left) and Bulkhead C can be seen at the back (to the right). | Figure 4: Bonding areas for Bulkhead A | Figure 5: Bonding areas for Bulkhead C |
Bonding Scenario | Design Requirement | Loading Scenario | Expected Stress | Notes |
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Chassis and Bottom Panel | Structural | 2G Bump | Tensile | This analysis laid the foundation for adhesive selection |
Vehicle Crash Scenarios | Shear | |||
Bulkheads to Chassis | Strong enough to allow mounting of potential dynamic assembly parts | 2G Bump | Shear | Later in the analysis, bulkheads were concluded to not be structural which led to ceasing its analysis. Documentation is still written for educational purposes. |
Vehicle Crash Scenarios | Tensile |
Safety Factor of Adhesives can be found on this page:
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