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Composites Testing

Before manufacturing the rims, the manufacturing process used needs to be validated through various tests of the composite materials used. There are multiple tests that are standard for any composite materials, and will be taken from general composites testing data used for other parts of the car: (1) tensile testing, (2) compression testing, (3) flexural strength testing, and (4) delamination tests. There are more specific tests to be done to test for the specific function and geometry of the rims. For now, this list includes: (1) pressure testing (80-120 psi), (2) buckling testing, and (3) environmental testing. The data can be used to validate the simulations done in ANSYS. More detail on each test and associated information:

1. Tensile test
2. Compression test
3. Flexural strength testing
4. Delamination testing

1. Tensile test
2. Compression test
3. Flexural strength testing
4. Testing void content

Composite properties derrived from tests above depend on the quality of the composite layup. One of the most important parameters to measure the quality of the composite part is void content. The density of the voids in the composite can affect many properties of the composite, especially the transverse properties of a unidirectional composite. This void content can be used as a score of how well the layup turned out, and different manufacturing methods can be compared. Void content should be kept below 1% for a good composite, and it is discouraged to use composites with a void content of >5% for critical applications. This number can be measured by following ASTM standard D2734-16, attached to this page.

ASTM D2734-94

Rim Specific tests

1. Pressure testing
2. Buckling testing
3. Environmental testing
4. T-Joint testing

Sources:

The Winning Solar Car.pdf

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