Designing an automotive chassis is not an intuitive process. It, at times, can be very difficult depending on the geometry of the structure. Research was conducted at the University of Cincinnati to alleviate the burden of this task. Software tools were developed to help speed the design process. A new technique of measuring the torsional stiffness of a Formula SAE chassis design was created. Finally, a recommended process is presented to perform the design and validation of a Formula SAE chassis.
As engineers we turn to different tools that we have access to in order to understand and iterate a design. In the area of space frames, design tools can be limited. To get an understanding of a chassis design, engineers turn to Finite Element Analysis (FEA) to gain a better understanding of these types of structures. Ultimately, manual iterations are not enough to completely optimize a structure to a desired goal. Software tools need to be developed in order to have a deep understanding of how the structure performs at each iteration. Two tools, a sensitivity and optimization tool, were written and the outcome of each is discussed.
Until 2007, the UC Formula SAE team has validated only the current year’s frame design and not the entire chassis design. In the world of Formula One racing it is essential to have knowledge not only of frame stiffness but also hub to hub chassis stiffness.Various ways to test chassis stiffness were investigated and designed. A static test was developed and performed. A finite element model and its correlation to this static test is discussed.