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FB Chassis Design and Analysis Guide

The document discusses the chassis subsystem and provides information on what a chassis is, research on chassis design, and the design process. It explains that a chassis is a tube frame used for roll cages and kit cars. It discusses different rod thicknesses used and compliance with the rulebook. The design process considers dependencies on other subsystems and uses simulation software to test impacts and adjustments.

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f20231099
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186 views16 pages

FB Chassis Design and Analysis Guide

The document discusses the chassis subsystem and provides information on what a chassis is, research on chassis design, and the design process. It explains that a chassis is a tube frame used for roll cages and kit cars. It discusses different rod thicknesses used and compliance with the rulebook. The design process considers dependencies on other subsystems and uses simulation software to test impacts and adjustments.

Uploaded by

f20231099
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Chassis

Subsystem
01
What is a
chassis
02
Research and
Rulebook
Research
The FB chassis is nothing but a tube frame
chassis, and this kind of chassis is mainly
used for Roll cages in production vehicles
for extra bracing, and kit cars.
To start with a tube frame chassis, we
must understand basic principles of a rod,
before the entire structure, its
compressive, tensile, bending, shear,
twisting characteristics.
Research
In FB, there are three kinds of rods used,
based on the thickness and area of cross
section. The thickest one is used for the
front and main hoops, along with the
harness mounts. Next ones are used for
side and shoulder impact structures. The
smallest ones are used for supports and
bracings.
Research
Either using Ansys or pre-existing research papers, we can find all the
tolerances of these three rods, to find out their breaking/fracture points.

Sample analysis I ran on


Ansys a while back with
the help of PS1 mentor
Rulebook
As for chassis, the rulebook is quite
strict and precise. Specific wheel base
measurements, wheel clearances,
driver clearances, ground clearance,
specific, angle requirements of hoops,
and such specifications have been
noted down. I have found various
papers for various FSAE chassis
designs and research on tube chassis in
general.
03
Design Process
Design Process
For the Design process, we must start with the interdependencies of
chassis subsystem with the other subsystems.
● Powertrain
Dimension, weight, mounting points, thermal clearance and hot spots
of the motor and the drivetrain (half shafts, CV joints, chain sprocket
system, differential) will be required
● Accumulator
Dimension, weight, mounting points, thermal clearance and hot spots
of the battery and its supporting equipment (BMS etc.)
Design Process
● Electronics
Dimensions and mountings of the ECU, harness details so that harness
management along the chassis can be implemented
● Suspension
Probably the most important subsystem when it comes to chassis
design, both subsystems will work closely for finalising the type of
suspension, its mounting, geometry, tolerances etc. Need to do more
research in this aspect of the vehicle
● Braking
Mounting points, tolerances required
Design Process
Once all the interdependencies are finalised, the actual design work can
begin. We can start with basic sketches of wireframe diagrams of the
preliminary chassis, and then add tubes and welded joints to it. First few
iterations will go through a lot of adjustments, with inputs and suggestions
from the other subsystems (minute adjustments such as suspension
geometry, battery position etc). Along with this, we must test the structure
on Ansys software for various kinds of impacts (front, side, rear collisions
and rollovers) and make adjustments accordingly.
Thanks!
CREDITS: This presentation template was created by Slidesgo, and
includes icons by Flaticon, and infographics & images by Freepik

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