Optimization of Formula SAE CFRP Monocoque for improvement of the ratio between Torsional stiffness and Mass

In Formula Student competitions, the use of composite monocoques has become common practice, since they offer higher torsional stiffness at a lower weight than traditional tubular steel frames. Therefore, this Master’s thesis investigates the optimization process of the Formula SAE CFRP monocoque of the Formula Student team of the Politecnico of Torino. After an overview of the Formula SAE environment, necessary to understand the context of research and competitiveness, the thesis work presents a benchmarking analysis of leading FSAE teams and motorsport categories in order to identify best practices in weight reduction strategies and cockpit opening design solutions. The core of the research focuses on the optimization of the SC26 cockpit geometry, identified as the most critical monocoque region from a torsional point of view. Several sensitivity analyses have been performed through a developed FEM model to evaluate the influence of geometric parameters such as cockpit height, width, fillet radii, hook profile, and core thickness on torsional stiffness, aiming to improve the ratio between torsional stiffness and mass. In conclusion, this work establishes validated guidelines for the optimization of CFRP monocoques for Formula Student applications, achieving a substantial improvement in terms of torsional stiffness compared to the previous team's prototype.