International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 10 Issue: 05 | May 2023
p-ISSN: 2395-0072
www.irjet.net
Design & Development of Formula Student Chassis Krunal Kania1, Aditya Verma2, Rushang Babariya3, Jayendra Vasani4 1,2,3 Student, Automobile Engineering, L.D. College of Engineering, Gujarat, India
4Assitant Professor, Automobile Engineering, L.D. College of Engineering, Gujarat, India
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This research primarily focuses on the design &
monocoque where the rear structure is made up of tubes while the frontal part consists of carbon fibre layups as per the assembly requirements.
development of the FSAE chassis frame. The chassis is basically a structural bracket to fit all vehicle subsystems like the powertrain, suspension, etc. It is a base with room for enhancement by reducing the weight & increasing the structural rigidity without hampering the performance of a high-speed vehicle.
1.1 Design Methodology For the season 2022-23, the spaceframe chassis was designed using Solidworks CAD modeling software. As the team had prior experience in spaceframe chassis design, there was enough room for optimization before jumping onto a monocoque frame design. The material selected was AISI 4130 after comparing various available criteria to match season goals which will be discussed in upcoming topics.
For a formula student team, either spaceframe or monocoque chassis can be developed while keeping in mind the FS events’ guidelines. Besides achieving structural rigidity & torsional stiffness, an efficient design should also make an improvement in weight reduction & ease of manufacturing & manufacturability. A final spaceframe chassis completes all the checkboxes to make a vehicle with an important consideration of ergonomics (95th percentile) and driver inputs for the best drive positions. This research paper shows the criteria the team played with and the methods used to improve the final design.
The table below shows the basic range of dimensions to choose for the tubes according to Formula Bharat 2022 rulebook. Table -1: Chassis tube nomenclature & dimensions
Key Words: Chassis, Spaceframe, FSAE, Solidworks, Ergonomics, AISI 4130, Tube notching, Jigs & fixtures, Manufacturing.
Tubes
Nomenclature
Dimensions (mm)
MOI (mm2)
Primary
Front Bulkhead
25.4 x 2.5
11320
25.4 x 1.65
8509
18 x 1
6695
Front Hoop
1.CHASSIS
Main Hoop
The chassis is a base for the development of a formula-styled student vehicle. Designing an efficient chassis is a very important part of the vehicle's performance. It holds together all the subsystems like tractive systems, electric powertrain, suspension & wheels, driver & equipment, etc.
Secondar y
Front Hoop Bracing Side Impact Main Hoop Bracing
Tertiary
Mainly, the chassis is designed according to the rules & guidelines of Formula Student Events. Goals for the design team were the chassis weight ≤ 28 kgs, better flexural strength, torsional rigidity 2000 Nm with ease of manufacturing & fabrication, taking into account the driver’s ergonomics & performance during dynamic events.
Bracing Supports Non-Structural Tubes
Initially, an envelope was designed with the focus to understand positioning of subsystems with reference to the driver. This helped the team mark the basic sketch with all reference points. Then, driver inputs using Ergo Jig were taken to initially set the angles for the roll hoops, and the maximum horizontal cockpit space required was decided.
FSAE chassis are made of spaceframe or monocoque. Spaceframe chassis is a set of tubes welded together with triangulation for efficient load transfer across all tube members. Different sizes and dimensions are used in tubes according to the load acting on them. Materials like AISI 1080, AISI 4130, etc. can be used for the tubes. On the other hand, monocoque chassis is a single material bracket made up of lightweight materials like carbon fibre or aluminium sheets. They can also be made as semi-
© 2023, IRJET
|
Impact Factor value: 8.226
|
ISO 9001:2008 Certified Journal
|
Page 1796