Composite monocoque frames are becoming increasingly more popular inperformance cars. Compared to their steel and aluminum counterparts theyprovide additional torsional stiffness at the cost of less weight. This thesiscovers the complex optimization process of a monocoque applied within theregulations of a Formula Student competition. It aims to give the reader a goodunderstanding of the rules and how they affect the optimization process whilegenerating an optimized design used in the competition of Formula StudentGermany -21 by KTH Formula Student. The rules of Formula Student dictate the structural requirements on themonocoque based on a steel space frame. All materials except low carbon steelused in the structure require proof of equivalence through regulated testingmethods. However, this thesis shows that the regulated setup can severelyaffect results through a deep analysis of the testing methodology.The torsional stiffness of the monocoque is analyzed and optimized accordingto the results of a free-size optimization. Both through slight adjustmentsin chassis geometry and the laminate, resulting in a theoretical torsionalstiffness of 9.9 kNm/deg, more than five times as much as the old space frame.Weighing in at 20 kg, a significant weight reduction of about 10 kg, eventhough it was larger, with a surface area of about 4.2 m2. This design will be the first monocoque manufactured within KTH FormulaStudent since 2010. Therefore, a lot of focus was put on analyzing the rulesand lay the ground for future development by conducting tests on optimizedpanels. These results have the potential to further reduce the weight of a futuremonocoque with a different geometry. / Allt fler sportbilar använder självbärande karosser i komposit. Till skillnadfrån deras stål och aluminium motsvarighet så tillåter kompositkonstruktionenen styvare konstruktion för samma vikt. Denna rapport går igenom denkomplicerade optimeringsprocessen för en självbärande kaross i kolfiber appliceratinom tävlingen Formula Student. Målet med rapporten är att läsaren ska fåen bättre förståelse av reglerna och dess påverkan på optimeringsprocessensamtidigt som en optimerad design presenteras för användandet i “FormulaStudent Germany -21” åt KTH Formula Student. Reglerna inom Formula Student ställer strukturella krav på den självbärandekarossen baserat på en standard för stålrörsramar. Alla material förutomlåg kols stål som används i strukturen kräver att ekvivalens bevisas genomspecifika tester. Denna rapport visar att dessa tester kan generera olika resultatgenom en djup analys av metodiken. Torsions styvheten av karossen analyseras och optimeras enligt reglernagenom en så kallad free-size optimization". Genom att variera geometri ochkomposit utvecklades en kaross som var mer än 5 gånger så styv som dentidigare stålrörsramen med en teoretisk torsions styvhet på 9.9kNm/deg. Meden vikt på 20 kg reducerades även vikten 10 kg, även om den var större, ochhade en area på cirka 4.2m2. Denna design kommer att vara den första självbärande komposit karossentillverkad inom KTH Formula Student sedan 2010. Efter den djupa analysen avreglerna, testas då de optimerade panelerna, vilket lägger grunden för framtidautvecklingen. Dessa resultat har potential att reducera vikten ytterligare av enframtida kaross, genom ändringar i geometrin.

The Master’s thesis deals with the design and production of a composite chassis of the new formula Dragon X. The carbon prepreg used for manufacturing of the monocoque was to be operated at high temperatures. Therefore, this thesis deals with the application of composites structures in the high temperature environment. The thesis addresses the torsional stiffness problematics and it was not only physically tested, but also simulated by FEM analysis and the results were compared.

This master’s thesis deals with use of central spring unit at Formula Student car. Thanks to CFD simulations, aerodynamics properties of the car was found out according to different position of suspended mass. Within kinematic design of both axles a parameters of spring unit of both axles were defined as well. Whole design was made to increase overall performance of the car thanks to the aerodynamic forces.

Master’s thesis is focused on a design of front uprights for Dragon 8 racing car of TU Brno Racing Formula Student team. This thesis follows up the bachelor’s thesis called “Race Car Front Wheel Carrier Design”. Discussion about team’s recent upright and component designs is followed by a model creation with use of topology optimization. Final geometry is simulated in FEA software. Design of the upright is then compared to the previous designs and also to its substitute produced with milling machining process.

This master thesis represents a step forward in vehicle dynamics of TU Brno Racing Formula Student team from Brno University of Technology monoposts. A detailed research focused on light automotive wheels. Its main part is to design and make a composite wheel for a formula monopost Dragon 9. The wheel design was formed from the rules side, car packaging, forces acting and limits of composite parts production. There’s a collection of CAD documentation of wheel designs, moulds and connected fixtures. The designed moulds for hollow carbon fiber wheels were manufactured. The technology in making of composite wheels is described in detail. Also, the ways of testing the wheel before a straight use on a race car were designed. There are several wheel prototypes made as an outcome of this thesis. The wheel design is reviewed in terms of functionality and manufacturing side of things.

Design of braking system for Formula Student vehicle. Braking system is one of the most important control system in every vehicle, even more in race car application. Only perfectly working braking system is capable bring the best results. In this diploma thesis are list of used parts with basic force calculation, design of pedal assembly in accordance with the rules of Formula Student, options for measuring and dataloging from ride for next development.

This master’s thesis deals with the design and manufacture of a heat exchanger with polymeric hollow fibers for a Formula Student vehicle. The work can be divided into three parts. The first part contains a review of heat transfer and heat exchangers, the second part deals with polymeric fiber heat exchangers design and manufacture of of polymeric hollow fibers heat exchanger with a heat exchanger for a Formula Student vehicle. The last part deals with the comparison of polymeric hollow fibers heat exchanger with the original aluminum heat exchanger and the evaluation of the measurement results.

Pavel Chalupa Torsional Stifness Analysis of Formula Student Frame Modification DW, IAE, 2010, 66 str., 66 obr. This thesis is concerned with a calculation analysis of a frame construction for Formula Student. The Base design of this construction is modeled in computer program ProEngineer. In next step the model is transfered to calculation software Ansys. The analysis is made by finite element method in torion and bend there. The calculation of torsional stiffness is made of resultant values. Finally, the results are compared with previous frame versions.

Martin Lhota Formula Student Front Chassis Part Design DW, IAE, 2011, 75 pp, 62 pics The aim of the thesis is to suggest a suitable configuration of Formula Student Car’s front part of a frame according to current rules of SAE organization in the Formula Student competition. In this proposal low weight, manufacturability and sufficient torsion rigidity were preferred, whereas previously suggested solutions were reflected. At first there is presented a list of important SAE rules for the construction of front part followed by a short recherché of development of the constructional solution of frames and frames suitable for Formula Students car. Secondly there is described process during frame construction design and its computational model for the analysis which simulates torsion with the support of MKP system. Gained results and some parameters of the frame are compared with similar version of the frame construction which was suggested and made for the first Formula Student Car of our University. Moreover, there is also presented summary of suggested frame and also recommendation with possible alternatives for the next development.

Diploma thesis focuses to design anti roll-bar for Formula Student car Dragon II build in FME. This work follows the proposal anti roll-bar car Dragon I of Jan Krasula. Task of this work is analyses last design, introduce more effective method treatment, create own design with parameters which will be better then last design. An integral part design is prepare manufacture documentation which will be base for manufacture of this komponent