Using FEA simulations to guide

your monocoque conception

by Formule ETS

FSG Academy 2020/2021 powered by

Formule ETS

Samuel Gagné Steve Groleau

Chassis Lead Technical Director - Power & Drive Lead
s.gagne.formule.ets@gmail.com s.groleau.formule.ets@gmail.com

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Formule ETS

1988 1993
First Formula Car First Composite Parts

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Formule ETS

2004 2010
First Hybrid Chassis First Full Monocoque

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Formule ETS

2013 2017-2019
First Full Aero Package APEX Last Monocoque Concept

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Formule ETS

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Using FEA simulations to guide your
monocoque conception
▪ 1. Typical ETS season
▪ 2. Design process
▪ 3. Simulations
▪ 4. Manufacturing
▪ 5. Recommendations
▪ 6. Questions

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1.1 – Car development

▪ Monocoque concept (3 year design)

▪ Reduce cost
▪ Manufacturing time (Learning curve)

▪ First year : Design, mold manufacturing, learning

▪ Second year : Fixing problems, reliability
▪ Third year : Optimization & performance

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1.2 - Team structure
Team Technical
Captain Director

Aerodynamic Dynamics Chassis Electronics Power &

Treasurer Leader Leader Leader Leader Drive Leader
Media
Sponsors
Static Events

Mechanical
Rules/Safety Ergonomics Simulations
Design

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Using FEA simulations to guide your
monocoque conception
▪ 1. Typical ETS season
▪ 2. Design process
▪ 3. Simulations
▪ 4. Manufacturing
▪ 5. Recommendations
▪ 6. Questions

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2.1 – Design objectives
▪ First meeting of the season
▪ Design review
▪ Lessons learned
▪ Failure reports
▪ Major problems etc.

▪ Second meeting
▪ Team objectives
▪ Design guidelines

Front Engine Support

Chassis Attachment Failure

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2.1 - Design objectives Testing
2017 245 km
2018 508 km
▪ Giving a ponderation to 2019 831 km
every concept of your
design to guide conception
choices
▪ Weight
▪ Compliance
▪ Manufacturing facility
▪ Lead time
▪ Specific stiffness
▪ Etc.

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2.2 - Iterative designs

▪ Influence of any aspect of your design

▪ Understanding
▪ Compromise
▪ Main objectives
▪ Different materials

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Using FEA simulations to guide your
monocoque conception
▪ 1. Typical ETS season
▪ 2. Design process
▪ 3. Simulations
▪ 4. Manufacturing
▪ 5. Recommendations
▪ 6. Questions

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3.2 - Simulation Circumstances
▪ Why
▪ Important structure
▪ SES regulated
▪ Simple simulations
▪ Simple and mandatory
validations

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3.3 - Meshing

▪ Convergence
▪ Compromise between the
accuracy of results and
processing time

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3.3 - Meshing

▪ Concentration of stress
or singularities
▪ Creates false results

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3.4 - Layup Preparation

▪ Great preparation
produces a great
simulation

▪ Thickness
▪ Type
▪ Specifications
▪ Density
▪ ASTM D3039

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3.5 - Virtual layup
▪ Most important
improvement that
can be made to
the design of the
monocoque
▪ Carbon fiber is
heavy

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3.7 - Preparing the simulation
▪ Constraining the part

▪ Important for good

results
Fixed support
▪ Reduces the calculation
time when done right

Compression support

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 3.8 - Understanding the results

▪ Using the right results

Weight Weight on full car Deflection
Iterations Description
g lbs kg lbs mm
1 no core 214,0 0,47 21,40 47,19 49,5
2 6,25mm core 220,3 0,49 22,03 48,56 9,6
3 12,7mm core 226,5 0,50 22,65 49,94 4,9
4 19mm core 232,8 0,51 23,28 51,32 3,2
5 6,25mm core LD 220,2 0,49 22,02 48,55 10,4
6 12,7mm core LD 226,5 0,50 22,65 49,93 5,6
7 19mm core LD 232,7 0,51 23,27 51,29 3,7
8 19mm core no anti-crush 254,7 0,56 25,47 56,15 3,1

▪ Identifying the decisive factor

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3.9 - Performance Factor
Performance
Weight Deflection
Iterations Description Failure Total
40 60
1 no core 40,00 0,00 0 0,00
2 6,25mm core 32,90 16,91 1 49,81
3 12,7mm core 26,19 36,75 1 62,94
4 19mm core 19,83 59,22 1 79,06 6,25mm core
5 6,25mm core LD 32,98 15,18 1 48,16
6 12,7mm core LD 26,26 31,81 1 58,07
7 19mm core LD 19,94 50,19 1 70,13
8 19mm core no anti-crush 0,00 60,00 1 60,00

KPI
80

70
12,7mm core
60

50

40

30

20

10 19mm core
0
1 2 3 4 5 6 7 8

Weight Deflection
*THIS IS A FICTIVE SCENARIO*
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Using FEA simulations to guide your
monocoque conception
▪ 1. Typical ETS season
▪ 2. Design process
▪ 3. Simulations
▪ 4. Manufacturing
▪ 5. Recommendations
▪ 6. Questions

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4.1 - Manufacturing

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4.1 - Manufacturing

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4.1 - Manufacturing

Mold preparation Wearing gloves

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4.2 - Miscellaneous optimisation

▪ No anti-crush ▪ With anti-crush

▪ Impossible to manufacture ▪ Reduces weight
▪ Provides false results ▪ Real-life situation
▪ Provides more accurate results
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4.3 - Manufacturing

2013 core design 2014 core design

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4.3 - Manufacturing

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Tips and tricks

▪ Keep it simple in the beginning

▪ Isotropic materials to verify the model
▪ Start with simple parts of the vehicle

▪ Importance of composite preparation and manufacture details

▪ Mold preparation
▪ Make sure to pay close attention during the manufacturing phase to
reduce risks of delaminations
▪ WEAR GLOVES!

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Thank you for your attention

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