STEP 6 optimize and discussion

6.2 AErodrnamics

REDUCE DRAG

REAR WING

6.3 Seat and belt joints

Belt

The simulation show that the maximum stress is at the contact area(not accurate) and the inner ring due to force distribution pull the surface area of inner ring and strech out which can be improved by changing material to something stronger or use bigger ring to have more volume to withstand and distribute force.

Seat

The simulation show that the maximum stress is at the floor due to low thickness of the floor sheet which can be improve by using stronger floor material or spread force to bigger area by using bigger support bar. 

6.4 Impact attenuator and Impact attenuator plate

Impact attenuator (IA)

Interested in conducting a study to explore alternative IA designs that can effectively absorb a greater amount of energy while maintaining a lightweight profile and facilitating easier manufacturing compared to the existing design. One popular IA design that has gained recognition is the honeycomb structure. However, it can be challenging to manufacture on our own as it often requires specialized equipment or needs to be purchased pre-cut. Nevertheless, there is another design approach that shows promise in enhancing the efficiency of IA, which is the sandwich structure.

The sandwich structure involves the use of multiple layers with different properties, typically consisting of a lightweight core material sandwiched between two outer layers. This design provides enhanced energy absorption capabilities while maintaining a lightweight construction. The core material can be selected based on its ability to deform and absorb energy during impact, while the outer layers provide structural integrity and distribute the forces evenly.

One advantage of the sandwich structure is that it offers flexibility in terms of material selection. Various materials, such as foams, composites, or polymers, can be used to optimize the IA's performance based on specific requirements. Additionally, the manufacturing process for sandwich structures is relatively more accessible compared to intricate honeycomb designs, allowing for easier fabrication and customization.

By exploring the implementation of sandwich structures in IA design, we can potentially achieve a lightweight solution that excels in energy absorption while being more feasible to produce independently.

Impact attenuator plate (AIP)

Indeed, the utilization of composite materials may be considered to reduce the weight of the AIP. The current design is relatively heavy, and it would be beneficial to explore options for weight reduction in this aspect.

Composite materials consist of a combination of two or more constituent materials with distinct properties, typically a reinforcement material embedded in a matrix material. The reinforcement material, such as carbon fibers or fiberglass, provides high strength and stiffness, while the matrix material, such as epoxy resin, acts as a binder and protects the reinforcement.

By incorporating composites into the AIP design, we can take advantage of their excellent strength-to-weight ratio. Composite materials are known for their lightweight nature, making them an ideal choice for weight-sensitive applications. By reducing the weight of the AIP, we can enhance the overall efficiency and performance of the IA system.

Moreover, composites offer the advantage of tailoring their properties to specific requirements. By varying the type, orientation, and volume fraction of the reinforcement fibers, we can optimize the AIP's mechanical properties to meet the desired energy absorption and deformation characteristics.

While the implementation of composite materials may involve additional considerations in terms of manufacturing techniques and costs, the potential benefits of weight reduction and improved performance make it a promising avenue worth exploring in the design of the IA system.