Space Frame Chassis Research Articles

Static Analysis of Tubular Space Frame Chassis of an Electric Racing Car Made of ASTM A106 Grade B

Static Analysis of Tubular Space Frame Chassis of an Electric Racing Car Made of ASTM A106 Grade B

Shape Grammar and Formal Aesthetic Functions Spatial Relationship for Car Chassis Design

The developing of computer tools accelerate the designs phase for designers but the aesthetics of product appearance cannot be neglected. Shape grammar is a general computational language that manipulates shapes to generate designs. By defining the spatial relationships between those forms and how the forms are related to each other, shape rules can be written. Shape grammar was used as a tool for observing spatial relationships of design elements and principles of a space frame chassis and using biomimicry theory to give inspiration and ideas to create the new concept of supercars chassis design.

Non destructive testing and analysis of friction stir welded aluminium alloy 2024 pipes

Welded pipe is the most common structural part for conveying gas, water and wastes. The space frame chassis design of ground vehicles uses small diameter pipes. The present study examines the volumetric defects in Friction stir welded Aluminium Alloy 2024 pipes. The macroscopic examination by visual inspection and dye penetrant inspection and radiographic inspection for microscopic examination carried out on welded pipes to find surface and sub surface defects. The result is analyzed to find the effect of FSW process parameters like tool rotational speed, pipe welding speed and tool pin length on full weld penetration and defect free microstructure of small diameter pipe joints. The tool rotation speed of 1460 rpm and 4.5 mm tool pin length provided defect free welded joints.

Numerical analysis on space frame chassis of a formula student race car

The present work aims to design and perform the numerical analysis on the space frame chassis of a formula student race car using computer aided software tools by proposing a new chassis style that meets the standard rules of FSAE. The chassis style could be a distinctive one as a structural component to stiffen the weaker, open cockpit section that has not been done before in FSAE. The space frame chassis was modelled in CATIA, and the analysis was carried out using SOLIDWORKS software. For the proposed space frame chassis, the different load tests were conducted viz. Frontal Impact, Torsion test and side impact test. It was observed that the proposed space frame chassis design is a safe one for the driver. As many works are available in the same format, but as we observe that while designing the space frame, triangulations are provided to increase the strength of the space frame and to reduce the degree of freedom of the chassis to make it stiffer. The load paths are the main thing which we taken care of while designing the chassis so that with the minimum number of tubes only the design criteria was taken care and the rules and guidelines are complying.

Design optimisation of braided composite beams for lightweight rail structures using machine learning methods

Braided composites have seen substantial industrial uptake for structural applications in the past decade. The dependence of their properties on braid angle provides opportunities for lightweighting through structure-specific optimisation. This paper presents an integrated approach, combining finite element (FE) simulations and a genetic algorithm (GA) to optimise braided beam structures in the spaceframe chassis of a rail vehicle. The braid angle and number of layers for each beam were considered as design variables. A set of 200 combinations of these variables were identified using a sampling strategy for FE simulations. The results were utilised to develop a surrogate model using genetic programming (GP) to correlate the design variables with structural mass and FE-predicted chassis displacements under standard loads. The surrogate model was then used to optimise the design variables using GA to minimise mass without compromising mechanical performance. The optimised design rendered approximately 15.7% weight saving compared to benchmark design.

A Review on Design and Analysis of Tubular Spaceframe Chassis

A Review on Design and Analysis of Tubular Spaceframe Chassis

Experimental analysis and Validation of torsional stiffness of a Tubular space frame chassis

Chassis is the pat that integrates all components of the vehicle and withstands the load. This load includes the weight of each component and the force that occurs when the vehicle is moving (acceleration, deceleration, and cornering). Chassis should also absorb energy when a collision occurs. The chassis provides a path for the forces that act on it. The suspension pickup points on the chassis are an important parameter in determining the suspension geometry of the vehicle. Torsional Stiffness is determined by the amount of Torque required to deflect the chassis by unit degree. The differences in forces from the suspension linkages that leads to a Twisting Moment. The moment will deflect the chassis about its Roll Axis. Predictable handling of a race car may be achieved by tailoring sis stiffness so that roll stiffness between sprung and un-sprung masses is due almost entirely to the suspension. In this work, the effects of overall chassis flexibility on roll stiffness will be determined using a finite element model (FEM) of a Formula Student Chassis and suspension. The Validation of the model is done by designing and fabricating a test rig to experimentally determine the Torsional Stiffness. The Suspension linkages are replaced with equivalent length solid tubes to eliminate the suspension compression. The test rig will be capable of applying force through one of the front wheel hubs, the other end of the front axle is kept at zero load. The deflection in chassis can be calibrated using a dial gauge.The objective of this project is to Design and optimize the design of the chassis for meeting the Chassis Stiffness target value to obtain the best Lateral Dynamics. Increasing the Torsional Rigidity will reduce the twist in the Chassis, improving vehicle handling by allowing the suspension components to control a larger percentage of a vehicle's kinematics.

Design, stimulation and fabrication of chassis of an FSAE female driven vehicle

Abstract Formula student competitions are a type of design and fabrication competition held across the world. Chassis is a very important component of any vehicle which is designed keeping in mind all the other components of vehicle like suspension, brakes, engine requirements, etc. as well as ergonomics and driver comfort as per the rules of the competition This study focuses on design, optimization and ANSYS analysis of a chassis designed around a 95-percentile male dummy as well as female driver comfort. The chassis was tested for front bulkhead impact, rear bulkhead impact, vertical bending and torsion analysis under static conditions and optimized to give a design with least weight, least cost in manufacturing and fabrication, maximum possible torsional rigidity and safety. A spaceframe chassis was designed using cold rolled tubes of AISI 1018 using SolidWorks and tested on ANSYS at all major points of force applications. 1.22 FOS was obtained in front bulkhead impact test, 1.7 FOS was obtained in rear bulkhead impact test, FOS of 1.15 was obtained in torsion test and 1.49 FOS was obtained in vertical bending test of the chassis in FEA analysis. The chassis obtained had the optimum values of safety and comfort and provided cheapest method for manufacturing.

Design Analysis of Spaceframe Chassis for FSAE Vehicle

Design & Analysis of Spaceframe Chassis for FSAE Vehicle - written by Shobhit Agarwal , Prashant Awasthi , Tarun Saatyaki published on 2020/04/02 download full article with reference data and citations

FRONT AND SIDE IMPACT ANALYSIS OF SPACE FRAME CHASSIS OF FORMULA CAR

One of the popular types of formula car chassis is space frame chassis. There are many issues to design and analyze formula car chassis. For driver, Front and side impact are the main issue for design and analysis with accurate and safety. In this article, the 2017-2018 formula SAE (the Society of Automotive Engineers) rules are used for analysis. SolidWorks 2016 are used to construct the CAD models of formula car chassis. Finite element method (FEM) is used to analyze the CAD models using SolidWorks Simulation. The results show that all formula car chassis models satisfy the 2017-2018 formula SAE rules. For the front impact, the maximum stress and the maximum deflection are not significant affected by varying the distance of the side members. While varying the distance of the front impact members affects both of the maximum stress and the maximum deflection. For the side impact, the maximum stress and the maximum deflection are not significant affected by varying the distance of the front members. While varying the distance of the side members affects both of the maximum stress and the maximum deflection. The criterions of the formula car chassis design are to make maximum stress lowest and maximum deflection lowest. The distance of the front members joint and the distance of the side member joint should be as low as possible.

Design a Space Frame Chassis for Light Weight Automobiles for Improved Safety and Reliability

The objective of this research is to design a spaceframe chassis for light weight automobiles possessing unladen weight of ≤ 550Kg to replace the conventional monocoque type chassis frame. The maximum stress and maximum deflection that the chassis can resist without fracturing are important criteria. In this thesis, the existing monocoque chassis was considered and analyzed under static loading, frontal impact, side impact, rear impact, front rollover and side rollover loading conditions by using Finite Element Analysis method. Then, taking the test results as a reference, a spaceframe chassis was designed for the same size vehicle. The critical evaluation standard points stated in the Federal Motor Vehicle Safety Standard (FMVSS), U.S.A standard, were used as guideline to see the performance of the existing and the new chassis frames. The test results show that a space frame chassis has better stress resisting capacity and reliability than the conventional monocoque chassis frame under all impacts.

Efficacy of Vehicle Chassis of Polymeric Composite

Abstract Chassis is an integral part of any automobile. Chassis is solely responsible for bearing the entire vehicle's weight along with the payload. In today's industry, three most common types of chassis used are Ladder-frame chassis, Monocoque chassis and Spaceframe chassis. Ladder-frame chassis finds its use in most of the heavy weight vehicles, trucks and busses, whereas, monocoque and spaceframe chassis find their application in light commercial vehicles. This paper specifically talks about the ladder-fame chassis. Since the chassis is an integral part of any vehicle, the weight of chassis plays a significant role in determination of entire vehicle's weight which in turns affects many parameters related to the performance of the vehicle. Most of the industries use steel alloys to construct these chassis which in turn make the vehicle heavy. Modern advancements in Material Sciences has suggested use of Carbon Reinforced Epoxy based Polymeric Composites instead of Steel alloys for the manufacturing of these chassis. Carbon Reinforced Epoxy based Polymeric Composites are basically made of two components, viz, Carbon and Epoxy and the variation in volumetric composition of each, leads to significant changes in significant mechanical properties of the composites. This paper deals with the determination of exact volumetric composition of Carbon and Epoxy in Carbon Reinforced Epoxy based Polymeric Composites which would ultimately replace the existing steel alloys with the help of stimulation software, ANSYS. This paper also determines the exact cross-section of the chassis made with Carbon Reinforced Epoxy based Polymeric Composites which could eliminate the steel alloy chassis with existing cross-sections

Design and specifications of racing car chassis as passive safety feature

This paper reviews the design and test results for the main passive safety feature of Formula-type (Formula Student class) open-wheel racing cars: the tubular spaceframe chassis. Formula Student is an international competition for engineering students and young athletes, who work in teams to design racing cars, assemble them from scratch, and then race them. This paper presents a chassis strength analysis, the results of head-on and lateral crash tests, and torsional stiffness calculations for the chassis of a racing car used by the team representing the Shukhov Belgorod State Technological University, as proof that this particular structural design is safe for future use.

Optimization of Volumetric Composition and Cross-Section of Carbon Reinforced Epoxy based Polymeric Composite Tubes in Spaceframe Chassis

Abstract This paper focuses on the use of Carbon-Reinforced Epoxy based Polymeric Composite Tubes in place of regular AISI 4130 tubes used in manufacturing of the space-frame chassis of a car. The Automobile industry uses basically three types of chassis, viz, Space-frame chassis, Monocoque chassis and Ladder-frame chassis. The Chassis under study is chassis of an All-Terrain Vehicle and all the calculations and results are done with the help of ANSYS . The paper is basically divided into two parts. The first part deals with the variation of the composition of carbon and epoxy in the polymeric composite tubes and finding out the most accurate composition, which could be used to replace the existing material. The Second parts deals with the variation in the dimensions of the cross-sections of the tube and finding the most accurate dimension which could give competition to the existing norms. The major deciding factor taking in consideration was the maximum deflection observed under basic loading conditions. The paper concludes by comparing the weight of both the chassis, one using AISI 4130 tubes and one using Carbon-Reinforced Epoxy based Polymeric Composite Tubes.

Chassis Structural Design of Track Racing One Manned Formula Car

The current work contains the design and optimisation of a spaceframe chassis for a track racing one manned formula car able to participate in the Formula Society of Automotive Engineers (Formula SAE) 2017/2018. Materials, profile cross section types were selected by considering the theories of elastic failure. The structural strength of the chassis was determined by Finite Element Analysis using ABAQUS software by determining the stress distribution during static and dynamic loading in addition to exposing the modal frequencies. Beam elements were used in the finite element model as it provides accurate modelling of small deflection bending responses. A simple baseline chassis design was developed that adheres to the Formula SAE 2017/2018 rules. Optimisations were made in terms of the configuration and material utilisation of the chassis members were done to prevent yielding during the static loading of car components and dynamic loading during acceleration and cornering. Furthermore, the same method of optimisation was used in prevention of the coincidence of natural frequency with the frequency of the engine.

Design and optimization of FSAE chassis using FEA

According to the statistics of FSAE, teams prefer using spaceframe chassis because it is cheaper and easy to fabricate. The only disadvantage of the spaceframe chassis over a monocoque is the greater weight of spaceframe chassis. A spaceframe chassis also makes it easy to define the suspension hard points as the chassis members can be welded together according to whatever points are needed hence making its design easy. This work will be focusing on the spaceframe chassis. Analysis of different designs for the FSAE chassis based on all the design aspects including all rules and safety aspects of the car will be carried out. The analysis will be based on various conditions that the chassis may face during its use. These conditions include the roll, pitch and yaw conditions. The chassis would be analysed for frontal and side impact situations. Also, it would be made sure that all the chassis designs meet up with the optimum value of torsional stiffness. Our work aims at providing the optimum range for the torsional stiffness which can act as a guideline for other Formula student teams in the world. Also, this paper will define the parameters that need to be considered while designing, analysing, fabricating and testing the FSAE chassis.

Design of Electric Vehicle Racing Car Chassis using Topology Optimization Method

The goal of this project is to improve the design of space frame chassis of electric vehicle which meet the rules and regulations of Formula Varsity (FV) Malaysia. The chassis was designed using topology optimization method and analyzed for its structural performance using various loading analyses and RULA assessment.

Car Body and Chassis Development of UKM CARevo for Perodua Eco-Challenge 2011

This paper presents the development of the UKM Perodua Eco-Challenge vehicle, CARevo in terms of aesthetic design, novel fabrication of car body and superior chassis design. The objective of the competition was to develop a fuel efficient car which was competent to travel the longest distance using 0.5 liter of RON95 fuel with some rules and regulation verified by the Perodua to be followed. The UKM CARevo was powered by a 660cc fuel injection engine with manual 5-speed transmission with the total of 3450 mm, 1500 mm and 1106 mm for its length, wide and height. Several design such as space frame chassis design, composite bodywork result from fiberglass with resin, aerodynamic design of car body and are the key features that is discussed in this paper.

Design and Development of UTeM Perodua Eco-Challenge Vehicle

This paper presents the design and development of the UTeM Perodua Eco-Challenge vehicle. The aim of the project was to develop a new generation of fuel efficient car which able to travel the longest distance using 0.5 liter of RON95 fuel. The eco-car was designed as a single seat rear wheel drive vehicle powered by a 660cc fuel injection engine with manual 5-speed transmission and weighs of 355 kg with 30:70 load distribution. The key design features of the fuel efficient car were also discussed in this paper such as space frame chassis design, braking system, composite bodywork and suspension system. Modifications on the engine were also discussed such as engine management to further increase the vehicle fuel efficiency.

Campbellology for Ferrari

With the need to save weight, increase performance and reduce costs, in 1996 Ferrari opted to use an all aluminium spaceframe chassis for the 360 Modena car. The design partnership of Ferrari and Alcoa called for a mix of extrusions welded to 12 strategic castings. The present study describes how the foundry process and methods were developed utilising the John Campbell philosophy as a basis for achieving the quality targets for the casting components.