Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures

Hdl Handle:
http://hdl.handle.net/10545/621208
Title:
Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures
Authors:
Khan, Laraib Alam; Mahmood, Ali Hasan; Hassan, Bilal; Sharif, Tahir; Khushnod, Shahaab; Khan, Zaffar ( 0000-0002-5393-569X )
Abstract:
The advanced composite materials are increasingly being used in the automotives for their ultralight physical properties and super strong mechanical properties. This research examines the cost-effective single-step liquid resin infusion manufacturing process for developing all composite car body as the generally used sheet molding compound manufacturing process is highly capital intensive. Three different scaled down models of the Eco car were developed focusing on minimal weight and air drag coupled with aesthetics. Structural design and analysis was carried out using the Pro/E and Ansys tools. The Pro-E model was scaled up to generate computer-aided drafting drawings for tool development. Different stations were marked on the model and sliced virtually for development of pattern. Moreover, the mold was manufactured from carbon and glass/polyester composites for prototype manufacturing of the car body. This involved manual placement of desired number of carbon layers as preform on female side of the mold. The vacuum sucked the resin through a number of carefully selected entry ports which ensured effective resin distribution and impregnation. Polycarbonate wind shield was thermoformed in the convection oven according to streamlined geometry of car body and hinged. The car body was integrated with the compatible floor panels and accessories. The crumble zone shock absorber in the bumper was manufactured using successive layers of nomax honeycomb and polyvinyl chloride rigid foam to dampen the accidental shock. The car performed remarkably well in the Eco marathon race held at Malaysia, 35:97–104, 2014. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineers
Affiliation:
NED University of Engineering and Technology; Centre for Emerging Sciences, Engineering and Technology (CESET); GIK Institute for Science and Technology; Glyndwr University; University of Engineering and Technology
Citation:
Khan, L. A. (2014) 'Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures' Polymer Composites, 35 (1):97
Publisher:
Wiley
Journal:
Polymer Composites
Issue Date:
Jan-2014
URI:
http://hdl.handle.net/10545/621208
DOI:
10.1002/pc.22638
Additional Links:
http://doi.wiley.com/10.1002/pc.22638
Type:
Article
Language:
en
ISSN:
02728397
Appears in Collections:
Department of Mechanical Engineering & the Built Environment

Full metadata record

DC FieldValue Language
dc.contributor.authorKhan, Laraib Alamen
dc.contributor.authorMahmood, Ali Hasanen
dc.contributor.authorHassan, Bilalen
dc.contributor.authorSharif, Tahiren
dc.contributor.authorKhushnod, Shahaaben
dc.contributor.authorKhan, Zaffaren
dc.date.accessioned2016-12-21T09:53:06Z-
dc.date.available2016-12-21T09:53:06Z-
dc.date.issued2014-01-
dc.identifier.citationKhan, L. A. (2014) 'Cost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures' Polymer Composites, 35 (1):97en
dc.identifier.issn02728397-
dc.identifier.doi10.1002/pc.22638-
dc.identifier.urihttp://hdl.handle.net/10545/621208-
dc.description.abstractThe advanced composite materials are increasingly being used in the automotives for their ultralight physical properties and super strong mechanical properties. This research examines the cost-effective single-step liquid resin infusion manufacturing process for developing all composite car body as the generally used sheet molding compound manufacturing process is highly capital intensive. Three different scaled down models of the Eco car were developed focusing on minimal weight and air drag coupled with aesthetics. Structural design and analysis was carried out using the Pro/E and Ansys tools. The Pro-E model was scaled up to generate computer-aided drafting drawings for tool development. Different stations were marked on the model and sliced virtually for development of pattern. Moreover, the mold was manufactured from carbon and glass/polyester composites for prototype manufacturing of the car body. This involved manual placement of desired number of carbon layers as preform on female side of the mold. The vacuum sucked the resin through a number of carefully selected entry ports which ensured effective resin distribution and impregnation. Polycarbonate wind shield was thermoformed in the convection oven according to streamlined geometry of car body and hinged. The car body was integrated with the compatible floor panels and accessories. The crumble zone shock absorber in the bumper was manufactured using successive layers of nomax honeycomb and polyvinyl chloride rigid foam to dampen the accidental shock. The car performed remarkably well in the Eco marathon race held at Malaysia, 35:97–104, 2014. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineersen
dc.language.isoenen
dc.publisherWileyen
dc.relation.urlhttp://doi.wiley.com/10.1002/pc.22638en
dc.rightsArchived with thanks to Polymer Compositesen
dc.subjectCompositesen
dc.subjectSandwich structureen
dc.subjectModellingen
dc.subjectComposite car bodyen
dc.titleCost-effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structuresen
dc.typeArticleen
dc.contributor.departmentNED University of Engineering and Technologyen
dc.contributor.departmentCentre for Emerging Sciences, Engineering and Technology (CESET)en
dc.contributor.departmentGIK Institute for Science and Technologyen
dc.contributor.departmentGlyndwr Universityen
dc.contributor.departmentUniversity of Engineering and Technologyen
dc.identifier.journalPolymer Compositesen
dc.contributor.institutionDepartment of Physics; Centre for Emerging Sciences; Engineering and Technology (CESET); Islamabad Pakistan-
dc.contributor.institutionDepartment of Textile Engineering; NED University of Engineering & Technology; Karachi Pakistan-
dc.contributor.institutionDepartment of Mechanical Engineering; GIK Institute for Science and Technology; Toppi Pakistan-
dc.contributor.institutionAdvanced Composite Training and Development Centre; Glyndwr University; Unit 5, Hawarden Industrial Park Deeside Flintshire-
dc.contributor.institutionDepartment of Mechanical Engineering; Faculty of Aeronautical and Mechanical Engineering; Advanced Materials and Smart Structures Laboratory; University of Engineering and Technology; Taxila Pakistan-
dc.contributor.institutionDepartment of Physics; Centre for Emerging Sciences; Engineering and Technology (CESET); Islamabad Pakistan-
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