Required Tooling

Tooling List Spreadsheet

Overview to Composite Testing

The links below give a good overview to structural testing of composites, some test standards, and challenges/considerations we will need to account for.

https://www.addcomposites.com/post/mechanical-testing-of-composites

https://www.mentissciences.com/An-Introduction-to-6-Different-Types-of-Composite-Testing-1-12896.html

Required Tests

In the FSAE rulebook (section F.4.2), we must run tests on coupons replicating the structure of our monocoque in order to prove structural equivalence (this is not everything we may want to do in order to characterize our structure, more on that below):

• Center to center span of 400mm
• 50mm radius load applicator https://www.testresources.net/blog/a-complete-guide-to-the-three-point-bending-flexural-test | | Perimeter shear (F.4.2.5) | Force required to punch 25mm diameter indenter through the laminate, quantifying resistance to any intrusion to the structure | - Measure 100mm x 100mm at minimum
• Core and skin thicknesses need to be identical to what is in the structure
• Must meet force minimums of front bulkhead support (4kN) and side impact zone (7.5kN) | | Lap joint (F.4.2.6) | Measures force required to pull apart a joint of two bonded laminate samples | - Needs to fail the skin before the bond
• Joint design with single bond area needs to have two separate tests for shear and peel
• Joint design with two perpendicular bond areas only requires shear | | Harness attachment points (F.7.9) | Pull testing of harness hardpoints | - Each attachment point must support a minimum 15kN in tearout
• An attachment point where two belts meet has a minimum of 30kN | | Comparison test (F.4.2.3) | | |

Other Tests

The tests above are what’s required by the rulebook in order to pass SES, but we will likely want to conduct other tests to be able to properly characterize our structure and make it as lightweight and stiff as possible. This isn’t really a definitive list, but is a good starting point for what else we may want to run to help us in the design process.