Monocoque Workflow Plan

1. Identify Monocoque Design Goals
   1. General - What do we want from our new monocoque?
      1. What will be the MAIN focus (other than structural compliance)?
         1. Adaptability?
         2. Simplicity?
         3. Manufacturability?
         4. Aerodynamics?
         5. Ergonomics?
         6. Cost?
         7. In the end all will be considered, but what will take precedence over everything?
      2. Make mounting to the monocoque easier (flatter/straighter panels)
      3. Outer/inner main hoop?
      4. Do we design for EV/IC compatibility?
      5. Design a full monocoque?
      6. Two year design cycle or one year?
      7. What are the changes to car’s components to take into account?
         1. Accumulator is a big one, design will change a lot based on new accumulator
         2. Suspension Geometry would definitely change
   2. Aerodynamics
      1. Cover front shocks
         1. Can we move shocks forward? (problems with cross section)
            1. Much easier to package shock forward of the pedal box
      2. Provide space for removable aerodynamic devices
      3. Streamline the form
   3. Suspension
      1. Are there any major desired design changes?
   4. Electrical
      1. Are there any major desired design changes?
   5. Ergonomics
      1. Are there any major desired design changes?
   6. Manufacturing
      1. Reduce Panel Count
      2. Reduce Weight
      3. Play more with variance of ply count and core height/type
      4. De-mouldable geometry
   7. Overall
      1. Full monocoque will be hell without a reliable carbon/autoclave sponsor
         1. I am working on a list of composite companies in minnesota we could reach out for sponsorships
      2. Can we do it in 1 year? 2 years seems very doable, but 1 is very enticing
2. Identify Geometric Restrictions
   1. Minimum Wheelbase Length
   2. Percy Model
   3. Tire Exclusion Zone
   4. Rollover Protection Envelope
   5. Cockpit Entrance Template
   6. Internal Cross Section Template
   7. Side Impact Zone
3. Identify Component Space Claims
   1. PowerTrain
      1. Accumulator & Cover
      2. Drivetrain?
      3. I don’t really know
   2. Ergonomics & Driver
      1. Driver
      2. Seat
      3. Pedal Box
      4. Steering System & Wheel
      5. Headrest
   3. Design/Structural Requirements (Rules)
      1. Main Hoop + Bracing
      2. Front Hoop (no bracing required)
4. Design Initial Model
5. Test the Monocoque on current car setup
   1. Identify any obvious concerns
   2. Identify areas of change (ie. suspension setup, aero mounting, ergo setup, roll hoop)
      1. Suspension Setup & Mounting
      2. Aero Mounting
      3. Ergo Setup
      4. Roll Hoops Locations/Geometry
      5. Powertrain Setup
6. Begin Monocoque Analysis
   1. CFD Simulations
      1. Analyze the model’s aerodynamic impact
      2. Identify possible areas of change and improvement
         1. Could be changes to the monocoque or the aero package
   2. FEA/FEM Analysis
      1. Start heavy and stiff - Ensure initial rigid and stiff setup
      2. Identify Areas susceptible to failure and ones far from it
      3. Make the model more anisotropic - focus the strength in the directions and cases it requires it most

Testing

Geometric Limitations

Relevant Literature