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Steel Chassis PDF
Steel Chassis PDF
Eric Klang
Faculty Advisor
Wolfpack Motorsports
College of Engineering
North Carolina State University
Raleigh, NC 27695-7910
ABSTRACT
This paper is an introduction to the design, analysis, and
fabrication of a steel tube space frame chassis for use in
Formula SAE. A guideline for the construction of this
frame will be based upon the Wolfpack Motorsports
2009 car (WMF09) and may be used by nearly every
amateur formula car racer that would like to build a car
for him/herself.
INTRODUCTION
The Formula SAE competition requires the construction
of a new car for every competition year. The 2008
Wolfpack Motorsports effort was disappointing due to
the underestimation of the difficult construction of a steel
space frame chassis.
Having built carbon fiber
monocoque chassis for several years before 2008, the
team was inexperienced in the design and fabrication of
a full steel frame. As a result, the WMF08 was never
raced at an official competition, leaving it eligible to be
used in the 2009 competition. However, the FSAE
Rules committee implemented a minimum size
requirement for all 2009 chassis and the 2008 frame
would not have met this requirement, so a new frame
had to be built.
packaging issues for the driver and the fuel tank. These
issues were resolved by moving the driver forward and
having the seat lean more horizontal than in previous
years.
Driver Position and Controls Another important aspect
of chassis design is driver positioning and controls. If the
driver is not able to operate the car comfortably, it will
not meet its full potential. Driver comfort concerns
include seating angle, elbow space, head height in
relation to the front of the car, and controls operation
(pedals, shifter, and steering wheel).
Driver Seating The seating position in the car was
determined mainly from having the driver test different
seat back angles in a plywood seat mockup. It was
determined that an angle between 45 and 50 degrees
from horizontal is ideal for having a drivers chest and
head low enough and for comfort. Decreasing the back
angle from 65 degrees in the 2008 car to 45 degrees
drops the drivers chest by nearly 2 inches. The
shallower seat angle has a positive effect in that it
moves the drivers head and chest lower and therefore
lowers the overall center of gravity of the finished car.
With the drivers head lower, it will be more difficult for
short drivers to see over the front roll hoop and
bulkhead. However, since the members of the team that
are competition drivers are between 511 and 62, it
was decided that the shallow seat would be kept.
One advantage of the 2009 rules change on cockpit size
is that it allows the driver to have more elbow room
when driving. With the driver able to place his/her
elbows where necessary, it becomes easier for the
driver to operate the steering wheel and clutch in the
car. The steering wheel is operated with greater ease
due to the driver being able to have more leverage in the
cockpit.
Controls Operation - As part of the new chassis design,
a redesign of the 2008 pedal box was in store. The
2008 box flexed considerably under braking causing a
loss of driver feel and even a drop in braking
deceleration. After careful investigation of the front
portion of the new chassis design, it was determined that
a pedal box could be built into the chassis using steel
tubing. This pedal arrangement is much stiffer than the
previous carbon plate and should provide better braking
characteristics for the car.
TorsionalStiffness =
VerticalDeflection
)
MomentArm
InputTorque
AngularDeflection
The input moment arm is half of the track width and the
input torque is the torque caused by the input
suspension loads on the front a-arms. These suspension
loads are estimated to be anywhere from 200 to 400 lbf
for an FSAE vehicle. Suspension loading is a function of
weight transfer and static loading. This load is applied to
the front while the rear lower a-arms are pinned,
simulating an absolute maximum torque the chassis
could encounter.
CONCLUSION
The completion of the chassis is a major annual
milestone for every FSAE team. A completed chassis
provides motivation to complete other parts of the car
because the team members can now visualize what has
been in the design phase for months. Every team sets a
goal to complete their frame early, giving them a chance
to test the car for two or three months before each
competition, but frequently there are delays. These
delays can range from financial difficulties, materials
procurement problems, workshop limitations, and team
member skill development.
To finish the chassis by a deadline that is put in place by
the team, the designer needs to have his/her design fully
completed and frozen by the time construction starts.
Changing design points during fabrication can
significantly hinder progress because days or even
weeks will go by without any construction while the
designer is modifying their model. This can decrease
team morale and motivation to finish the project.
Steel tube space frame construction gives team
members an opportunity to learn basic fabrication skills
through sheet metal work, tube fitment, and welding.
This also instills a sense of pride in new members that
make tubes that are used in an integral part of the race
car.
Space frame construction also provides an
opportunity for veteran members to teach the new
members how the team operates and its standards
regarding finished part quality.
The chassis design and construction process is a
cornerstone of the FSAE project. The many details that
must be considered during this procedure provides great
practice to aspiring engineers and gives them a leg up
on their competition.
ACKNOWLEDGMENTS
The authors would like to thank Max Koff, Drew Ulrich,
and the rest of the Wolfpack Motorsports members and
alumni for the support and advice during this project.
REFERENCES
1. kxcad. BEAM188. 14 Dec. 2008
<http://www.kxcad.net/ansys/ANSYS/ansyshelp/Hlp
_E_BEAM188.html>.
2. kxcad. SOLID187. 14 Dec. 2008
<http://www.kxcad.net/ansys/ANSYS/ansyshelp/Hlp
_E_SOLID187.html>.
3. Rouelle, Claude. Vehicle Dynamics and Race Car
Engineering Seminar (2008).