Finite element analysis and optimization of a Formula SAE car chassis

Abstract

In motorsport engineering, achieving the ideal balance between speed, agility, and safety is a monumental challenge. Formula SAE competitions, where collegiate racing teams design high-performance vehicles, emphasize the pivotal role of the chassis, the backbone of the racing machine. Ensuring chassis compliance with regulations and optimizing structural integrity and weight is a formidable task. This study addresses this multifaceted challenge by focusing on the development, simulation, and optimization of a Formula SAE car's chassis. Rigorous analysis of four chassis versions seeks to strike a balance between rigidity and weight, enhancing performance while adhering to rules. Longitudinal torsion, diamond torsion, lateral acceleration, and braking tests assess structural rigidity and stress distribution, ensuring predictability and preventing potential failures. The mesh uses one-dimensional elements (1 mm size) and material properties akin to SAE 1020 steel. The fourth iteration consistently demonstrated superior performance across all tests. Despite a slight weight increase, it exhibited a longitudinal torsional rigidity of 1985 Nm/deg, well-aligned with Formula SAE standards, and a formidable diamond torsional rigidity of 56,304 Nm/deg. Critical stress analysis during lateral acceleration and braking tests remained well within permissible limits, with a chassis weight of approximately 35 kg. In summary, this work meets stringent Formula SAE standards, offering a systematic methodology for chassis design and optimization. The fourth iteration excels in various critical tests and serves as a valuable contribution to motorsport engineering, providing a blueprint for enhanced competitiveness and performance in the 2023 Formula SAE Brazil competition.