Insert design for sandwich composite monocoque

Starting from 90’s the extensive use of Carbon fiber reinforced plastic (CFRP) has playing a key role in Motorsport and Super sport car. The main advantage of the use of CFRP structures is due to their high mechanical proprieties with the cons related to high materials and production costs. I fully discovered the composite world during my experience in the SquadraCorse PoliTO, the FSAE team of “Politecnico di Torino”. During the years 2014-2016, I designed a carbon fiber sandwich monocoque and many aerodynamic device (i.e. front main wings, side pods etc.) with the aim of reducing weight, assure safety and looking for performance. The lack of experience of the team in the composite world was effective, but with the help of ex-team member and many external companies across the whole design and manufacturing process, we realized a high performance composite Monocoque with higher performance in therms of specific Torsional stiffness with respect of the previous 10 years. Among all the design parameter of the Monocoque, the insert dimensioning was one of the most critical due to its high complexity and weight influence in the whole frame budged. For this reason, I yield this Master Degree Thesis in the insert design.