Desenvolvimento de um monocoque em fibra de carbono utilizando o método dos elementos finitos

Abstract

This study aims to design a new composite material monocoque for the prototype vehicle of the Pato a Jato team to reduce the vehicle's mass. Due to the complex nature of the structure and composite materials, Finite Element Method (FEM) analysis tools were chosen to assist in the design and analysis of the new structure. The process began with defining the analysis strategy, followed by selecting materials and determining boundary conditions based on critical scenarios the prototype might encounter. Subsequently, the structure's geometry was created to perform a preliminary modeling, using the simplified model to conduct mesh convergence and topology studies as a basis for subsequent steps. With the main conditions defined, an iterative design process was employed, using structural analyses to optimize the laminate configurations in terms of material, thickness, and orientation. With the laminate defined, structural analyses were conducted for each specific case, utilizing boundary conditions that aimed to closely resemble the real-world situations. Finally, post-processing of results was carried out, verifying the calculated deformation and stress values, along with a failure analysis of each laminate layer based on criteria specific to composite materials. Therefore, deformation and failure safety factor values were observed at levels considered acceptable in a structure that achieved a mass reduction of approximately 25% compared to the original structure.