Monocoque Chassis Design

I have used the reports of different colleges to prepare my report. I have posted few of the detail from fsae forum.

UNIVERSITY OF DELAWARE Completed Frame

Steel Frame Manufacturing •

Wooden Frame Jig is provided .Cheapest & Quickest to Manufacture.

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Complete all of the sections of the car that were parallel to the front bulkhead (Roll Hoops, Suspension Boxes, etc.)

Frame Analysis and Validation: Solid Works finite element analysis package was utilized to design and optimize the chassis. Many different chassis designs were analyzed using the same flexure and torsion tests in order to minimize the amount of frame members used while still maintaining proper stiffness •

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The Team than tested for Torsional Rigidity, Flexural Rigidity, Weight, Vertical Centre of Gravity

Alternative Frame Analysis :Modal Analysis Similar to the static finite element analysis performed, the chassis can be analyzed with Solidworks, using a technique called modal frequency analysis. This method will convert the frame to a mesh, and simulate vibrations through the chassis using several different frequencies. The frequencies that create the largest displacements are recorded, and the mode of vibration corresponding to each is also recorded. The results supply each resonant frequency, and the “mode shape” for each corresponding frequency.

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While Designing Chassis, Fuel Tank & Fuel System was taken into consideration. Due to the rules, a rigid Fuel tank, must be used for safety of  the driver.

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Finally Budget was showcased in the report of the college

The following report is of 

University of Toronato. The University has

posted a very detailed report of chassis design. They have also disused about composite monocoque chassis design. •

They have used software

Hyper Laminate for their composite

material Design. •

Allows inputs including material, weight restriction, ply thickness ratios, etc. and run multivariable design studies that would normally take weeks, and at great expense.

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Most FEA software packages have the capabilities of doing design studies, but with composite lay-up design, so many variables need to be changed, that there are very few powerful com- posite analysis packages that can quickly carry out this type of analysis.

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Another Software Altair Engineering

OptiStruct software was

used by the college.

Report of University of Florida was basic & very essential .It clearly stated the objective of Design of Chassis for fsae . The main design objectives for the chassis are: •

Research fundamentals behind designing a spaceframe that will see forces associated with a race car

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Research chassis materials that can withstand the high performance ratings of a formula style race car

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Design a chassis that will be able to withstand the loads from static and dynamic forces using solid modeling software

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Perform static and dynamic load analysis using finite element analysis software

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Optimize the chassis by lowering high stress concentration areas using better triangulation of the frame members and gusseting

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Finalize a chassis design that meets all requirements and regulations and begin testing of the vehicle once all the systems have been implemented into the vehicle Software NEi

Nastran can be used for finite element analysis

Below I have posted link of one video (manufacturing of fsae chassis) http://www.youtube.com/watch?v=850BBrzvB98

I have posted few details from fsae forum After going through one of the post from fsae form (the post was “justifying a monocoque chassis”) •

A good welding is required for a monocoque chassis.

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A max of 15-16 kg weight saving over a well designed spaceframe

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One BIG drawback with a carbon chassis is serviceability, especially component accessibility .

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The team can can go with rear section spaceframe chassis, but there are issuses with frame interface.