Design, simulation and manufacturing of composite rims for a formula-type race car

Abstract

This project is developed within the framework of the Formula Student Etech Racing team. It aims to be a guide in the design, calculation and manufacture of the vehicle rims in hybrid composite technology (although the theory mentioned can easily be extrapolated to different applications). Within the memory, a collection of the main characteristics and requirements applicable to the manufacture of components through composite materials is made, from which the design and manufacture of this component are based. A detailed guide reflects the different steps to follow in the manufacture of the carbon halves, both production processes to follow and the design of the tooling itself. A special mention is also made to the hub design, a structural part of the rim as the spokes are blended on it. In the extreme of them there is a special bolting pattern, different from the automotive standards. Finally, a study of the environmental impact confirms the fact that the manufacture of carbon rims is not dangerous for the environment, due to a low waste generated in manufacturing and a long life expectancy. About the concept of the wheel, there is a showcase of different wheel designs where one of them, the hub-less concept, can offer great performance in our future vehicles. Last but not least, the project cost shows the benefits of the self-develop parts in front of the commercial product.