How to project templates of carbon fiber for complicated surface?


How to project templates of carbon fiber for complicated surface?
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rhcp89
rhcp89
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Hello,


I'm studying on technical university and my job is to project (to model) the way the carbon fiber has to be put in mould which will be the negative of car body. In brief, my work will be used to create a body of a car of composites.

The problem is that the car body must be made of aerodynamic ,continuous shapes (no low-radius edges) so when the composite will be put then the unwanted folds may appear or that fiber will have to be cut in some places. I have no such an opportunity to make mould first and then put fiber on it as a test and given this, determine the way the templates should look like experimentally . I have to do it the other way round- I have to predict the shape of these templates given the 3d cad model of car body first.


So I would like to know are there any books, articles, methods etc, which tell how to cut that carbon templates for a given surface? Maybe there some graphics  which say how to determine the shape of these templates or software(I could import 3d model there)?

Thank you,Raportuj ten post
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brainfart
brainfart
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> I have to predict the shape of these templates given the 3d cad model of car body first.

This has been a problem for hundreds of years, think cartographers trying a projection of a round planet on a flat map without too much distortion. In your case, zero distortion on a body with complicated compound curves.
You can use the CAD software to determine the length of surface lines, the middle of a part (your zero) and several polar coordinates and determine the absolute minimum size of fabrics based on this data.

The cheapest way for good cutting patterns is an existing mold and newspapers, the most exact is probably some cheap glass cloth (twill or satin weave) laid into the mold and then stabilized with some tape.

GO

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