Learning objectives
Knowledge and understanding: Through lectures, seminars, educational visits and experimental labs, the student
will learn the design of structural elements of fiber-reinforced composites applied to the automotive field.
Applying knowledge and understanding: Upon successful completion of this course, the student will be able to apply
his/her knowledge to the selection of constituent phases (matrix and fiber), processing technology and to apply the
basic rules and tools to design composite material structures.
Making judgments: Through written reports and open presentation of the assignments and lab activities, the student
will be able to understand, discuss collectively and critically, as well as to expose, the results obtained.
Communication skills: Written reports improve the ability of presenting experimental data and general understanding
in an effective and concise way; group presentations allow to express the acquired concepts with an appropriate
language and to hold a discussion about the course topics.
Learning skills: the activities described so far, allow the students to acquire the methodological tools that are
necessary to continue their educational career and to become familiar with the ever-continuing update on scientific
achievements that is required in cutting-edge technological fields.
Prerequisites
Not mandatory, but appreciated:
- SCIENCE AND TECHNOLOGY OF METALLIC AND COMPOSITE MATERIALS
- FEM FUNDAMENTALS AND CHASSIS DESIGN
Course unit content
At the end of the course the students know:
- the common matrixes and reinforcements with a specific focus on automotive application;
- how to test composites for design purpose, incl. processing effects;
- fundamental theoretical and numerical tools for structural design with composites.
Full programme
The “Design of Racing Car Composite Structures” course is aimed at describing fundamental mechanical behavior and
design rules for fibre-reinforced polymers (FRPs) used in load-bearing elements, including the effect of constituents
and processing technology.
Frontal teaching activities will be backed by numerous lab activities designed to help students understand the most
common processing techniques and to familiarize with the main tests used to characterize the material for design
application.
- Applications of composites in the automotive field: fibre and matrix materials, processing technologies and
physical/mechanical properties;
lab on thermal and mechanical properties (DSC and DMA. Evaluation of Tg, optimization of cure cycle, effect of
temperature and creep phenomena);
lab on microstructure (determination of volume fractions for fibers, resin, and pores in FRPs);
lab on technology..
- Design and Analysis of FRP lightweight structures:
bulk composite laminates micromechanics, classical lamination theory, failure criteria, impact strength;
sandwich panels design rules;
bonded joints design rules;
lab on mechanical properties (tensile test, flexural test, effect of fiber orientation and volume fraction, effect of
stacking sequence in laminates);
lab on numerical/FEM modelling of stresses in FRP components
- Educational visits and seminars by companies representatives.
Bibliography
P.K. Mallick, Fiber-Reinforced Composites: materials, manufacturing and design – 3° Ed., CRC Press, 2008
Teaching methods
The course includes:
(i) lectures from academic providing principles and methods of broad applicability
(ii) lectures from industry expert introducing technical rules and practical approaches in the form of case studies;
(iii) experimental labs to understand the main tests currently used for the design with composites;
(iv) computer labs to learn and apply computational tools used in design development.
According to the authorization of the Director of the Department, in case of the impossibility of prof. A. Pirondi to be in the classroom for health reasons and after notifying the students, the lesson will be held online in a synchronous or asynchronous way.
Assessment methods and criteria
The examination comprises an oral presentation and discussion of assignments given by the teachers. The
assignements are developed in small groups (max 4 people). The examination consists of the discussion of the tech
reports associated with the assignments. The tech report includes: report in Word, PowerPoint presentation
(maximum duration 25 min) and any kind of material developed (simulation files, specimens, .). The evaluation, up
to 30/30, is based on the presence of the above elements, the comprehensiveness of the development of the
activities, the consistency and completeness of the description of the work performed, and the score is the same for
all group participants. Each of the assignments gives a maximum score of 30/n, where n is total number of
assignments. Cum Laude score can be attributed only with the unanimous opinion of the examination board. It can
be attained by students/groups that will distinguish over the expectations of the teacher(s), for instance by
performing design and simulations activities beyond those assigned, using methodologies not explained during the
course and demonstrating self-developed knowledge during the oral discussion. Lab reports, if presented and
properly done and discussed, contributes to the improvement of the score, including the achievement of Cum
Laude, up to 3/30.
Testi di riferimento
Other information
2030 agenda goals for sustainable development
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