Research and Concept Development
Hood Panel
The fastening method alternatives for the hood panel are aimed to be permanent, efficient installation, and cost-effective.
Surrounding panels: Side panel (driver’s side and passenger side), headlights, bottom panel and bulkheads?
Epoxy Adhesive
Applied to fix it to the side panels and bulkheads
Flush-Mount Blind Rivets
Flush-Mount Rivet
Aluminum and corrosion-resistant
Sizes diameter (Thickness of material): 3/32” (0.062”-0.125”), 1/8” (0.092”-0.625”), 5/32” (0.062”-0.5”), 3/16” (0.188”-1”), 1/4” (0.188”-0.375”)
Cost: ~$9.40 / 100 pieces
https://www.mcmaster.com/rivets/aluminum-flush-mount-blind-rivets/
Flush-Mount on both sides Blind Rivet
Zinc-plated, and mild corrosion resistance
Sizes diameter (thickness of material): 1/8” (0.059”-0.177”)
Cost: ~$10 / 50 pieces
https://www.mcmaster.com/rivets/flush-mount-on-both-sides-blind-rivets/
Calculations
1.1 Hood Mounting Methods & Locations
Calculation Assumptions:
Entire mass of vehicle is considered in the 2G bump force
Assuming worst case condition, where the entire load is applied in shear
Max. shear strength of LOCTITE® EA E-120HP adhesive = 20 N/mm^2 (is assumed to be equivalent to that of the adhesive being cured on Epoxy material for 12 hours @ 65 °C)
Table 1: Proposed Mounting Locations & Method for the Hood Panel
Bonding to Adjacent Panels | Method | Validation/Rationale |
|---|---|---|
Side panels | Epoxy Adhesive | Bonding area calculations (Excel attached, below) |
Windshield | Quarter-turn fasteners | Windshield must be removeable, quarter-turn fasteners will be used for windshield mounting to other panels |
Bottom Panels | Epoxy Adhesive | Modify hood panel to have inward curve along the bottom edge to allow the panel to join with the bottom panel. |
Hood-headlight bonding area validation:
