Integrated development of CFRP structures for a topless high performance vehicle

When modern saloon cars are re-engineered as convertibles (or roadsters) it is typical for them to lose 50% or more of the body’s torsional rigidity. Consequently the vehicles rarely handle quite as crisply, nor do they ride as well as the coupes from which they derived. This paper highlights the fundamental contributions of advanced composites in achieving the desired value of handling of the Murcièlago Roadster without penalizing the overall weight of the vehicle. To compensate for the absence of the roof structure, the vehicle was strongly redesigned by introducing new structural members and reinforcing existing critical components. A new all-carbon/epoxy composite sub-frame, which spans the entire engine bay, is comprised of elliptical tubular members, and it is the first of its kind in a production vehicle. Engineering of the sub-frame, from preliminary design to manufacturing decisions, is the focus of this paper, and is achieved through a Building Block approach that sets the program within the Integrated Product Development (IPD) strategy that the Advanced Composites Division of Automobili Lamborghini S.p.A. employs for its technology demonstrators. The strategy consists in a concurrent analytical and experimental development of the product, from the initial conceptual design and coupon testing, through the stages of element and subcomponent engineering, to final component manufacturing.