CN111806147A - FSAE racing car composite material rim and forming method thereof - Google Patents

Abstract

The invention relates to an FSAE racing car composite material rim and a forming method thereof, wherein the FSAE racing car composite material rim comprises an inner rim, an outer rim and a connecting disc, the inner rim is cylindrical, the outer rim is disc-shaped, the outer rim is installed on the end face of the inner rim through a connecting piece, the outer rim and the inner rim are both made of fiber materials, a sandwich layer is arranged inside the outer rim, the outer rim comprises an outer rim body and spokes integrally formed with the outer rim body, and the end parts of the spokes are integrally connected with the connecting disc. Compared with the prior art, the light weight of the rim of the FSAE racing car is higher, the unsprung mass of the racing car is effectively reduced while the heat dissipation performance of a wheel brake disc is ensured, and the lateral rigidity and the shock resistance of the rim are improved.

Description

FSAE racing car composite material rim and forming method thereof

Technical Field

The invention belongs to the technical field of FSAE formula racing cars, and particularly relates to a composite material rim of an FSAE racing car and a forming method thereof.

Background

The college equation automobile tournament (FSAE/Formula Student) is an automobile design and manufacturing race attended by the university automobile project or related specialty at the school team, similar to the college's F1 race. Each racing car team designs and manufactures a small formula racing car within one year according to the racing rules and the racing car manufacturing standards, and carries out all-round dynamic and static competition, such as cost, marketing, design, acceleration, durability, oil consumption and the like.

The rim is lightweight, unsprung mass of the FSAE racing car can be effectively reduced, and the rim has a vital effect on improving control stability of the racing car. At present, aluminum alloy rims and magnesium alloy rims are widely applied to FSAE racing cars, and most rim manufacturers take the FSAE rims as a part of the product development field. However, the composite material rim has not been widely used in FSAE events due to the reasons of high material price, complex process and poor durability and fatigue resistance, and there are few companies and enterprises using the FSAE racing carbon fiber rim as the product development field.

In the prior art, in patent No. CN101218110A, entitled "wheel", which is published by DYMAG racing company, the rim is made of plastic, the spoke unit or the wheel disc is made of metal, a plurality of connecting pieces in the form of bolts are arranged around the bottom of the rim in a circumferential distribution, and the connecting pieces are screwed into the threaded holes of the spoke unit or the wheel disc to form the rim; the hub is a long carbon fiber reinforced thermoplastic composite material automobile hub which is disclosed by Beijing Nasheng new material science and technology Limited and has the patent number of CN201420496310.2 and the patent name of the hub, combines the composite material with the carbon fiber, and has the characteristics of high strength, good heat dissipation performance and the like; the composite wheel is characterized in that a patent number CN205853745U published by China Headset Carlsberg Co., Ltd is adopted, the patent name is 'a combined wheel', the contact area of an aluminum alloy and a composite material body is increased through the structural design of a rotation stopping ring, the problems of reduced fastening torque, low reliability and wheel failure are solved, but the processing mode is more complex; the carbon fiber three-piece combined rim and the forming die thereof are disclosed by Harbin industry university (Weihai) with the patent number of CN110254128A, wherein the inner rim and the outer rim are bonded by high-strength sealant, and the inner rim and the outer rim are manufactured separately from the die. The patent of patent number CN207388741U, patent name "an integrated shaping carbon fiber composite rim" by Zhejiang university, this integrated shaping rim, its rim base all adopts the fillet transition with the spoke, avoids stress concentration, and the web adopts continuous fibers to be connected with wheel hub, uses groove structure to improve the junction of spoke and rim.

The structure and the forming method of the rim solve the problems of the structure and the forming of the rim under specific working conditions to a certain extent, but the research on the impact resistance of the rim is less, particularly for the rim for FSAE racing cars, the rim bears large lateral force and often alternating dynamic load, the requirements on the lateral rigidity and the impact resistance are particularly strict, and the requirements are difficult to meet.

Disclosure of Invention

The invention aims to solve the problems and provide an FSAE racing car composite material rim and a forming method thereof, which have good lateral rigidity and impact resistance and are easy to form on the premise of ensuring good braking heat dissipation performance.

The purpose of the invention is realized by the following technical scheme:

the utility model provides a FSAE cycle racing combined material rim, includes interior rim, outer rim and connection pad, interior rim is cylindric, outer rim is discoid, outer rim passes through the connecting piece to be installed interior rim terminal surface, outer rim and interior rim are made by the fibre material, and inside is equipped with sandwich layer, outer rim include outer rim body and with outer rim body integrated into one piece's spoke, the tip of spoke with the connection pad is connected as an organic wholely.

Further, the sandwich layer comprises but is not limited to foam or honeycomb materials, and forms a sandwich structure with the outer side fiber layer, so that the lateral rigidity of the rim is enhanced while the rim is lightened, the fiber material is a mixture of carbon fibers and aramid fibers, the aramid fibers can obviously improve the impact resistance of the rim, and the carbon fibers provide strength and rigidity.

Furthermore, the spokes are short and wide, the number of the spokes is 3-5, the oval holes are formed between the spokes, and the heat dissipation efficiency of the brake disc when the rim rotates can be guaranteed through the oval holes.

The tail end of the spoke is connected with the connecting disc through the mosaic structure, so that the spoke and the connecting disc can be prevented from moving under the rotating torque.

Further, the thickness of the rim of the inner rim and the outer rim is 6-8mm, and the height of the rim is 10-15mm, so that the lateral force transmitted to the inner side of the rim by the tire can be borne.

Furthermore, a groove structure convenient for assembling and disassembling the tire is further arranged on the circumferential surface of the inner rim, and bosses of 3-5mm are further arranged on the inner sides of the rim of the inner rim and the outer rim so as to prevent the tire from falling out of the rim under the extremely large lateral force of the racing car.

Further, the outer rim is composed of an outer layer of fiber laying layers and an inner layer of outer rim sandwich layers, the shape of each outer rim sandwich layer is matched with the outline of the outer rim body, the fiber laying layers are coated outside the outer rim sandwich layers, and the outer rim body is formed by combining the fiber laying layers and the outer rim sandwich layers.

Furthermore, the tail ends of the spokes of the outer rim sandwich layer are provided with wedge-shaped structures, the circumference of the connecting disc is provided with groove-shaped structures matched with the wedge-shaped structures, and the groove-shaped structures are connected in an embedded manner;

a boss structure is arranged on the end face of the connecting disc, and the fiber laying layer of the outer rim is lapped on the boss structure on the surface of the connecting disc;

the connecting disc is aluminium, the connecting disc terminal surface is equipped with a plurality of blind holes for be connected with the wheel mandrel.

Further, the thickness of the fiber layer is 1-5mm, and the thickness of the fiber layer at the rim of the outer rim is not less than 3 mm;

the fiber laying layer is bonded with the outer rim sandwich layer and the connecting disc through an epoxy resin adhesive film with the thickness of 0.2-0.3 mm.

Furthermore, the inner rim is provided with a flange plate used for being connected with the outer rim through bolts, an inner rim sandwich layer used for enhancing rigidity is paved inside the flange plate, and the thickness of the inner rim sandwich layer is 3-5 mm;

the outer rim is connected with the inner rim through titanium alloy bolts, and embedded parts are arranged in the bolt connecting holes, so that abrasion of a bolt knot structure is avoided.

A forming process of an FSAE novel composite material rim specifically comprises the following steps:

step 1, machining sandwich layers of an inner rim and an outer rim according to design requirements, and simultaneously machining embedded parts at flange connecting holes;

step 2, laying a carbon fiber and aramid fiber laying layer on the surface of an outer rim die, carrying out local reinforcement on the rim of the outer rim, and reserving the fiber laying layer for lapping with a connecting disc in the area of the connecting disc;

step 3, paving an epoxy resin adhesive film on the paved carbon fiber skin;

step 4, laying an epoxy resin adhesive film on the outer surfaces of the connecting disc embedded structure and the embedded part, assembling and bonding the adhesive film and the sandwich layer part, and covering and bonding the adhesive film and the sandwich layer part on the laid outer rim carbon fiber laying layer;

step 5, continuously paving carbon fiber and aramid fiber paving layers on the paved sandwich layer, and lapping with the paving layer paved in the step 2 to close the paving layer;

step 6, paving the inner rim by the same method as the steps 2-5, wherein the thickness of the paving layer is different according to different areas;

step 7, sealing the laid preforms, and vacuumizing;

step 8, putting the packaged workpiece into a hot-pressing tank, simultaneously carrying out vacuumizing in the bag and pressurizing treatment of inert gas outside the bag, and simultaneously carrying out heating and pressurizing treatment according to a curing curve of the used epoxy resin to cure and mold the workpiece;

and 9, cooling and releasing pressure, taking the product out of the hot-pressing tank, demolding, taking the product out, and performing post-treatment to obtain a finished product.

Compared with the prior art, the invention has the following advantages:

1. the utility model provides a FSAE cycle racing combined material rim compares with current FSAE aluminum alloy and magnesium alloy rim, alleviates the unsprung mass of cycle racing greatly, promotes cycle racing dynamics performance, is equipped with oval trompil between the rim spoke simultaneously, has guaranteed the heat dispersion of cycle racing brake disc.

2. According to the invention, the sandwich structure is formed by the sandwich material and the fiber at the outer rim and the spoke and at the flange on the end surface of the inner rim, so that the lateral rigidity of the rim is enhanced while the weight is reduced; the tail end of each spoke is provided with a wedge-shaped structure, and the periphery of the connecting disc is provided with a groove-shaped structure matched with the wedge-shaped structure, so that the play failure is prevented through assembly and bonding, and the reliability of the rim is enhanced;

3. according to the invention, based on the excellent impact resistance of the aramid fiber, the aramid fiber is mixed and laid in the carbon fiber laying layer according to a certain proportion, so that the defect of impact resistance of the carbon fiber composite material is made up on the basis of fully utilizing the advantages of high strength and light weight of the carbon fiber composite material, and the impact resistance of the rim main body is enhanced.

4. The forming method of the FSAE rim has the advantages that the inner rim and the outer rim are formed in a split mode, the mold processing difficulty and the part laying difficulty are reduced, the inner rim and the spokes are integrally formed, the overall strength and the rigidity are higher, the outer rim laying layer and the connecting disc are in lap joint, and the reliability of the rim is improved.

Drawings

FIG. 1 is a schematic view of the assembled rim of the present invention;

FIG. 2 is an exploded view of the rim of the present invention;

FIG. 3 is an exploded view of the outer rim and attachment disc of the present invention;

FIG. 4 is a schematic diagram of the structure of the connecting pad of the present invention;

FIG. 5 is a schematic view of the outer rim sandwich layer construction of the present invention;

FIG. 6 is a schematic structural view of an outer rim fiber lay-up of the present invention;

FIGS. 7, 8 and 9 are schematic views of the assembly structure of the connecting disc and the outer rim sandwich layer of the invention;

FIG. 10 is a circumferential surface configuration of the rim of the present invention;

figure 11 is a partial cross-sectional view of the outer rim of the present invention.

In the figure: 1-inner rim, 2-outer rim, 3-connecting disc, 4-epoxy resin film, 5-embedded part, 101-inner rim sandwich layer, 102-wheel rim, 103-boss, 104-groove structure, 201-fiber layer, 202-outer rim sandwich layer, 203-wedge structure and 301-groove structure.

Detailed Description

The invention is described in detail below with reference to the figures and specific embodiments.

Examples

According to the figures 1 and 2, the FSAE racing car composite material rim comprises an inner rim 1, an outer rim 2 and a connecting disc 3, wherein the inner rim 1 is cylindrical, the outer rim 2 is disc-shaped, the outer rim 2 is arranged on the end face of the inner rim 1 through a connecting piece, the outer rim 2 and the inner rim 1 are made of fiber materials, a sandwich layer is arranged inside the outer rim 2, the outer rim 2 comprises an outer rim body and spokes integrally formed with the outer rim body, and the end parts of the spokes are connected with the connecting disc 3 into a whole. Wherein, the sandwich layer includes but not limited to foam or honeycomb material, and the fibrous material is carbon fiber or aramid fiber.

Like figure 3, the spoke is short and wide, and the spoke figure is 3 ~ 5, is equipped with oval trompil between the spoke, and the radiating efficiency of brake disc when the rim rotates can be guaranteed to oval trompil, like figure 7, 8, the spoke end is connected through mosaic structure with connection pad 3, can prevent spoke and connection pad 3 and take place the drunkenness under the rotation torque.

As shown in figure 10, the thickness of a flange 102 at the edge of the inner rim 1 and the outer rim 2 is 6-10mm, the height of the flange 102 is 10-12mm so as to ensure that the flange can bear the lateral force transmitted to the inner side of the rim by the tire, a groove structure 104 for facilitating the loading and unloading of the tire is further arranged on the circumferential surface of the inner rim 1, and a boss 103 with the thickness of 3-5mm is further arranged on the inner side of the flange 102 of the inner rim 1 and the outer rim 2 so as to prevent the tire from falling out of the rim under the extremely large lateral force of the racing vehicle.

As shown in fig. 3, 5 and 6, the outer rim 2 is composed of an outer layer of fiber layer 201 and an inner layer of outer rim sandwich layer 202, the shape of the outer rim sandwich layer 202 is matched with the outline of the outer rim body, the fiber layer 201 is coated outside the outer rim sandwich layer 202, and the two layers are combined to form the outer rim body.

According to the technical scheme, as shown in fig. 9, the tail ends of the spokes of the outer rim sandwich layer 202 are provided with wedge-shaped structures 203, as shown in fig. 4, the circumference of the connecting disc 3 is provided with groove-shaped structures 301 matched with the wedge-shaped structures 203, the wedge-shaped structures and the groove-shaped structures are connected in an embedded mode, as shown in fig. 7 and 8, the end faces of the connecting disc 3 are provided with boss structures, the fiber laying layer of the outer rim 2 is lapped on the boss structures on the surface of the connecting disc 3, the connecting disc 3 is made of aluminum. The thickness of the fiber layer 201 is 1-5mm, and the thickness of the fiber layer 201 at the rim of the outer rim 2 is not less than 3 mm; as shown in FIG. 11, a fiber layer 201 is bonded to an outer rim sandwich layer 202 and a connecting disc 3 through an epoxy resin adhesive film 4 with a thickness of 0.2-0.3 mm.

As shown in fig. 2, the inner rim 1 is provided with a flange plate for being connected with the outer rim 2 through bolts, an inner rim sandwich layer 101 for enhancing rigidity is paved inside the flange plate, and the thickness of the inner rim sandwich layer 101 is 3-5 mm; the outer rim 2 is connected with the inner rim 1 through titanium alloy bolts, and embedded parts 5 are arranged in bolt connecting holes, so that the abrasion of bolt pairs is avoided.

The production process of the carbon fiber rim comprises the following steps:

step 1, processing sandwich materials 4 at the flange of the inner rim and sandwich materials 5 at the spoke of the outer rim according to design requirements, and simultaneously processing embedded parts at the connecting hole of the flange;

step 2, laying a carbon fiber layer with the thickness of not less than 1mm on the surface of an outer rim die, and locally reinforcing the wheel edge of the outer rim to ensure that the thickness of the carbon fiber layer is not less than 3mm, particularly, reserving the carbon fiber layer with the thickness of 1mm for lapping with a connecting disc in the area of the connecting disc;

step 3, laying an epoxy resin adhesive film 7 with the thickness of 0.2-0.3 mm on the laid carbon fiber skin;

step 4, laying a glue film 7 with the thickness of 0.2-0.3 mm on the mosaic structure of the aluminum connecting disc 3 and the outer surface of the embedded part, assembling and connecting the glue film with the sandwich material 4, and covering and adhering the glue film on the carbon fiber skin of the laid outer rim 2;

and 5, continuously paving a carbon fiber paving layer with the thickness not less than 2mm on the paved inner rim sandwich material 4, and closing the paving layer.

Step 6, paving the inner rim by the same method as the steps 2-5, wherein the thickness of the paving layer is different according to different areas;

step 7, sealing the laid preforms, and vacuumizing;

step 8, putting the packaged workpiece into a hot-pressing tank, simultaneously carrying out vacuumizing in the bag and pressurizing treatment of inert gas outside the bag, and simultaneously carrying out heating and pressurizing treatment according to a curing curve of the used epoxy resin to cure and mold the workpiece;

and 9, cooling and releasing pressure, taking the product out of the hot-pressing tank, demolding, taking the product out, and performing post-treatment to obtain a finished product.

In the embodiment, the carbon fiber material is type T700, and the gram weight is 220g/m²The aramid fiber of the prepreg material is Kevlar-49, and the gram weight is 200g/m²The prepreg of (1). The two materials were mixed at a ratio of about 3: 1, but in different structures, the material proportion should be different so as to give full play to the material performance.

In the embodiment, the weight of the obtained composite material wheel rim is 1.83kg, the composite material wheel rim is lighter than an aluminum alloy wheel rim by about 40 percent and lighter than a magnesium alloy wheel rim by about 19.3 percent, and the lightweight effect is obvious; the lateral rigidity is 3406.98N/mm, can satisfy the operating mode demand of FSAE cycle racing.

The embodiments described above are described to facilitate an understanding and use of the invention by those skilled in the art. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.

Claims (10)

1. The utility model provides a FSAE cycle racing combined material rim, includes interior rim (1), outer rim (2) and connection pad (3), interior rim (1) is cylindric, outer rim (2) are discoid, outer rim (2) are installed through the connecting piece interior rim (1) terminal surface, its characterized in that, outer rim (2) are made by the fibre material with interior rim (1), and inside is equipped with sandwich layer, outer rim (2) include outer rim body and with outer rim body integrated into one piece's spoke, the tip of spoke with connection pad (3) are connected as an organic wholely.

2. The FSAE racing composite rim of claim 1, wherein the sandwich layer comprises but is not limited to foam or honeycomb material, and the fiber material is a mixture of carbon fiber and aramid fiber.

3. The FSAE racing composite rim as claimed in claim 1, wherein the spokes are short and wide, the number of the spokes is 3-5, and oval holes are formed between the spokes;

the tail end of the spoke is connected with the connecting disc (3) through an embedded structure.

4. An FSAE racing composite rim according to claim 1, characterized in that the thickness of the rim (102) of the edges of the inner rim (1) and the outer rim (2) is 6-8mm, and the height of the rim (102) is 10-15 mm.

5. An FSAE racing composite rim according to claim 4, characterized in that the inner rim (1) is provided with a groove structure (104) on the circumferential surface for facilitating tire loading and unloading, and the inner rim (1) and the outer rim (2) are provided with a boss (103) of 3-5mm on the inner side of the wheel flange (102).

6. An FSAE racing composite rim according to any one of claims 1 to 5, wherein the outer rim (2) is composed of an outer layer of fibre lay-up (201) and an inner layer of outer rim sandwich layer (202), the outer rim sandwich layer (202) is shaped to match the profile of the outer rim body, the fibre lay-up (201) is coated on the outside of the outer rim sandwich layer (202), and the two are combined to form the outer rim body.

7. An FSAE racing composite rim according to claim 6, characterized in that the end of the spoke of the outer rim sandwich layer (202) is provided with a wedge-shaped structure (203), the circumference of the connecting disc (3) is provided with a groove-shaped structure (301) matched with the wedge-shaped structure (203), and the wedge-shaped structure and the groove-shaped structure are connected in an embedded mode;

a boss structure is arranged on the end face of the connecting disc (3), and a fiber laying layer of the outer rim (2) is lapped on the boss structure on the surface of the connecting disc (3);

the connecting disc (3) is made of aluminum, and a plurality of blind holes are formed in the end face of the connecting disc (3) and used for being connected with a wheel spindle.

8. An FSAE racing composite rim according to claim 7, characterized in that the thickness of the fiber lay-up (201) is 1-5mm, the thickness of the fiber lay-up (201) at the rim of the outer rim (2) is not less than 3 mm;

the fiber laying layer (201) is bonded with the outer rim sandwich layer (202) and the connecting disc (3) through an epoxy resin adhesive film (4) with the thickness of 0.2-0.3 mm.

9. An FSAE racing composite rim according to claim 1, characterized in that the inner rim (1) is provided with a flange for bolting with the outer rim (2), an inner rim sandwich layer (101) for enhancing rigidity is laid inside the flange, and the thickness of the inner rim sandwich layer (101) is 3-5 mm;

the outer rim (2) is connected with the inner rim (1) through titanium alloy bolts, and embedded parts are arranged in the bolt connecting holes.

10. A forming process of an FSAE novel composite material rim is characterized by comprising the following steps:

step 1, machining sandwich layers of an inner rim and an outer rim according to design requirements, and simultaneously machining embedded parts at flange connecting holes;

step 2, laying a carbon fiber and aramid fiber laying layer on the surface of an outer rim die, carrying out local reinforcement on the rim of the outer rim, and reserving the fiber laying layer for lapping with a connecting disc in the area of the connecting disc;

step 3, paving an epoxy resin adhesive film on the paved carbon fiber skin;

step 4, laying an epoxy resin adhesive film on the outer surfaces of the connecting disc embedded structure and the embedded part, assembling and bonding the adhesive film and the sandwich layer part, and covering and bonding the adhesive film and the sandwich layer part on the laid outer rim carbon fiber laying layer;

step 5, continuously paving carbon fiber and aramid fiber paving layers on the paved sandwich layer, and lapping with the paving layer paved in the step 2 to close the paving layer;

step 6, paving the inner rim by the same method as the steps 2-5, wherein the thickness of the paving layer is different according to different areas;

step 7, sealing the laid preforms, and vacuumizing;

step 8, putting the packaged workpiece into a hot-pressing tank, simultaneously carrying out vacuumizing in the bag and pressurizing treatment of inert gas outside the bag, and simultaneously carrying out heating and pressurizing treatment according to a curing curve of the used epoxy resin to cure and mold the workpiece;

and 9, cooling and releasing pressure, taking the product out of the hot-pressing tank, demolding, taking the product out, and performing post-treatment to obtain a finished product.

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