Development of an automated fibre placement-based hybrid composite wheel for a solar-powered car

Abstract

Substantial range, handling and acceleration improvements in high-performance vehicles can be achieved by weight reduction. An important area for weight reduction on a car is the wheels. A novel prototype carbon fibre/epoxy wheel has been developed using a combination of automated fibre placement (AFP) and hand layup for the Sunswift 7 solar car. A three-piece wheel design that utilises each process where best suited has been analysed and optimised using the ANSYS ACP PrepPost suite, manufactured, and mechanically tested. The wheel disc was produced using AFP and featured selective reinforcement in the form of spokes. The AFP fibre paths for the disc have been optimised using CGTech’s VERICUT VCP and VCS to minimise gaps and overlaps, resulting in a 98.9% reduction in overlaps when compared with the unoptimised layup. The rim and tyre mounting region of the wheel have been manufactured using hand layup and adhesively bonded to the disc. This hybrid manufacturing approach has demonstrated an advancement in the feasibility of combining traditional and automated composite manufacturing. The final wheel weighed 3352 g, and the wheel deflection under a compressive load has been experimentally verified within 3% of the theoretical value.