Mechanical Integration for Monocoque Chassis

This lecture presents a project from the EPFL Racing Team focused on the mechanical integration of a monocoque chassis, particularly on the modeling and integration of inserts to manage forces. The team transitioned from a steel tube chassis to a carbon structure, using aluminum inserts to transfer forces. Analytical models were used to determine critical forces for the inserts, followed by simulations to verify load-carrying capacities. Inserts were machined and tested for properties, along with composite plates to assess their capabilities in the chassis. The lecture also covers the design of support plates for stability during testing, and the results obtained from experimental tests to determine the maximum load-bearing capacity of the inserts.