Carbon Fibre Aerofoil (Delta)

General Composites Discussions Showcase
#1

Hi guys. As im sure some of you are aware I can not post many pictures up of our work items, however this one is a little different as it is for one of our cars!

This is a carbon fibre rear wind for a 1980’s Formula one car that races in historic races around Europe. This wing is layed up in top and bottom halfs that are then post bonded together, there is also a Nomex Honeycomb core inside.

Hope you enjoy the pics and any questions please feel free to ask.

Regards

Matt


2013-07-15_20_02_15 Wing1 by dobsonm, on Flickr


2013-07-15_20_01_42 wing2 by dobsonm, on Flickr


2013-07-15_20_00_35Wing3 by dobsonm, on Flickr


2013-07-15_20_00_13Wing4 by dobsonm, on Flickr

#2

If anyone would like to see any Pics of the tooling or construction methods and some construction pics please let me know and I will post them up.

Regards
Matt

#3

I would love to see them!

Jon

#4

Nice work Matt, would love to see pics of the car and tooling/construction.

#5


2013-07-14_15_03_23 by dobsonm, on Flickr
This is the upper skin with the peel ply removed just before bonding. you can see the honeycomb.


2013-07-14_15_03_14 by dobsonm, on Flickr
Showing the honeycomb. note that the edges of the honeycomb have a chamfer to stop bridging at the edge.


2013-07-14_15_00_54 by dobsonm, on Flickr
Showing the joggle on the leading edge to allow the two halfs to be joined without a step on the seam.


2013-07-14_14_57_38 by dobsonm, on Flickr
The top and bottom skins held together with clico skin pins around the spars to enable fitment before any glue is put anywhere near!
Note the peel ply was still on the parts at this point so reduce any risk of contamination of the mating faces.


2013-07-14_14_56_30 by dobsonm, on Flickr


2013-07-14_14_56_23 by dobsonm, on Flickr
The mould in the background of this shot is the mould for the top skin of the wing.

Hope you find these helpful and let me know if you want to know anything else about this aerofoil manufacture.

Matt

#6

That’s a chamfer on the core! j/k :stuck_out_tongue:

In the aero industry I’m used to 20°-30° ramps on 3/4"-1" core.

What thickness and cell shape did you use?

#7

Wait, how do the pins work again? I see the ones on the rear are through flanges, but how about the front?

Also, how much extra resin does the honey comb absorb?

#8

The core is 1/8" with 1/8" cells, the chamfer is approx. 35 degrees (cut by hand).

The pins splay out to the size of a swelled rivet and when squeezed by the pliers reduce in dia. so that they can be pulled out.

The lay up stack for each skin is:
3k 200g 2x2 twill at 0/90
3k 200g UD carbon tape along leading edge only
3k 200g 2x2 twill at 45
3k 170g plain weive Kevlar at 0/90 (stops short of component edges)
1/8" Nomex Honeycomb
3k 200g 2x2 twill at 45
3k 200g 2x2 twill at 0/90
Peel ply

That is the basic stack, there are a few additional localised placements of fibres but I would rather not go into those in public (they are also very dependent upon the use and specific profile of each wing).

#9

Nice job, my question is why you guys used Kevlar in here? is there a specific reason , and what about weight?

#10

Nice work, great surface finish as well!

I’m wondering what your process was for creating the plug and moulds? Especially the joggle joint?

fiberpro - one reason for the reinforcement would be for safety in a crash. The Kevlar should hold everything together in one piece, stops sharp carbon splinters from flying everywhere!

#11

That is the main reason for the Kevlar, however we also find that if the weight can be afforded, it reduces print thru from the honeycomb.

The main reason as I said tho is that if the aerofoil is subjected to an impact it will hold the wing together instead of the wing disintegrating to a pile of bits (depends upon the impact tho!

#12

Just curious, why does the honeycomb not extend fully across the wing, center area?

#13

There are spars that are in the centre area and the drop plates for mounting to the car, hence there is no H/c in that area.