design and analysis of chassis of student … and analysis of chassis of student formula race car...

DOI : 10.23883/IJRTER.2017.3060.Q4XBY 156

DESIGN AND ANALYSIS OF CHASSIS OF STUDENT FORMULA

RACE CAR

Raunak Mishra1,Shubhanandan Dubey 2 , Rahul Jaiswal3, Mustaque Mohammad4.

1, 2, 3 Department of Automobile, Theem College of Engineering, University of Mumbai, Maharashtra, India

Abstract—SUPRA SAEINDIA is one of the yearly organised national level competitions by the

Society of Automotive Engineers in India. Teams from all over India from various technical

institutes participate in this event. The teams are supposed to design, analyse and fabricate the F1

type race car in the campus premises itself. The sole focus of this paper is to find out the best and the

most suitable material for the chassis of SAE SUPRA student formula race car of team AVIATORS

in the year 2016. The chassis plays an important role in a race car and it is also considered as the

backbone of the race car. The chassis should be strong enough to withstand the shock loads,

vibration and other induced stresses as it has to sustain the racing environment. In the current work,

greater strength has been taken as the main dominating issue, so the dimensions of an existing space

frame chassis is taken for analysis with materials namely SAE AISI 4130 Carbon steel, SAE AISI

1020 Carbon steel, SAE AISI 4027 Carbon steel for the same load. The materials will be checked for

their performances in different loading conditions and the results will be compared for them. The

design process is purely based on SUPRA SAEINDIA 2015 rule book and the anthropometrical data

of the specified human (95th percentile male).The CAD software which is used for designing is

SOLIDWORKS 2015.A thorough study of static and dynamic loading conditions were done and

were analytically calculated. The correct boundary conditions were applied during FEA(Finite

Element Analysis)test which was carried out on ANSYS 2015.

Keywords—SAE INDIA, Tubular Space Frame chassis, chassis modelling, structural analysis.

I. INTRODUCTION

SUPRA SAEINDIA is one of the yearly organised national level competitions, in this event

the teams are supposed to design, analyse and fabricate the F1 type race car in the campus premises

itself. The number of the teams which participate annually in this competition is more than

185.Different technical inspections are done in two stages i.e. static and dynamic testing. The static

testing includes brake test, tilt test, cost report presentation, engineering design report and business

presentation. The dynamic tests include acceleration test, skid pad test and endurance test. The main

philosophy behind the impact test is that to assure the driver safety in the survival cell. The survival

cell should be strong enough to absorb the force and to distribute the force from front to the back

without large deflection to the chassis. The major tests which are carried out on the chassis to ensure

its safety are front impact test, side impact test and rear impact test.

For optimum performance of the chassis in different racing conditions it should meet

following criteria:

The material and manufacturing costs should be reasonable

It should have low centre of gravity

It should have minimum weight to stiffness ratio

II. PROBLEM STATEMENT

The objective of thesis work is to find out best and most suitable material for the chassis with the

constraints of equivalent stress and deflection of the chassis under maximum load condition. Design

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 03, Issue 03; Month - 2017 [ISSN: 2455-1457]

@IJRTER-2017, All Rights Reserved 157

and Analyze the space frame chassis using suitable CAE software is the main problem to be dealt

with for this work.

III. SOLUTION METHODOLOGY The solution for the problem can be obtained in three steps - Theoretical Analysis, Creation of the

Solid Model and Finite Element Analysis.

3.1. Theoretical Analysis: Theoretical Analysis is performed by using the basic concepts of

Strength of Materials. The Chassis of this problem is considered as a simply supported beam. Total

load acting on the Chassis is taken as a sum of capacity of the chassis and weight of the body and

engine throughout the span of the beam. By using the available data deflections at different points is

calculated.

3.2. Creating a Solid Model: A Three Dimensional solid model of space frame chassis is created on

the computer using Solidworks. This 3D Model is exported to Ansys for performing Finite Element

Analysis.

3.3. Finite Element Analysis: The steps involved in finite element analysis are: preliminary

processing, problem solving and post processing. In preliminary processing model is defined

according to their geometric structure, material of the model with its properties, geometry of element

including length, height, area and boundary conditions with load acting on the chassis. In problem

solving phase the mathematical equations for elements are derived and are solved simultaneously

with suitable boundary conditions. In post processing stage analysis is done and conclusions are

made according to the results.

IV. SPECIFICATION OF MATERIAL

Property SAE AISI 4130 SAE AISI 1020 SAE AISI 4027

Density

(g/cm3)

7.8 7.9 7.85

Yield strength

(MPa)

440 295

325

Ultimate Tensile

strength (MPa)

670

395

515

Poisons ratio 0.27-0.30 0.290 0.27-0.30

Shear Modulus

(GPa)

80 80 80

Young’s Modulus

(GPa)

190-210 200 190-210

Cost(Rs./Kg) 250 100 62.2

V. DESIGN CALCULATIONS FOR CHASSIS FRAME

Formulae:

For deformation = (PL^3) ⁄48EI

Where

P=force



L=length

I=moment of inertia

E= elastic modulus

VI. DESIGN OF CHASSIS FRAME USING SOLIDWORKS

Figure1. SOLIDWORKS model of Space Frame Chassis

VII. FINITE ELEMENT ANALYSIS OF CHASSIS USING ANSYS WORKBENCH The model of chassis is created in Solidworks and saved in IGES format so that it can be directly

imported into ANSYS workbench.

7.1. Applied Boundary Conditions:

Chassis frame weight

40 Kg

Total vehicle weight

350 Kg

Force -for front

9G=350*9*9.81=30000N

Force -for front

9G=350*9*9.81=30000N

Mesh size

2.54 mm

Acceleration due to gravity

9.81

7.2. Meshing and Structural Analysis of Chassis



Figure2. Mesh and Boundary Conditions for Space Frame Chassis

7.3. Structural analysis of Space Frame chassis in Front Impact

Figure3. Deformation contour of SAE AISI 4130 Carbon steel, SAE AISI 1020 Carbon steel, SAE

AISI 4027 Carbon steel

Figure4. Von Mises Stress Distribution of SAE AISI 4130 Carbon steel, SAE AISI 1020 Carbon steel,

SAE AISI 4027 Carbon steel



7.4. Structural analysis of Space Frame chassis in Rear Impact




SAE AISI 4027 Carbon steel

7.5. Structural analysis of Space Frame chassis in Side Impact






SAE AISI 4027 Carbon

VIII. RESULTS

VIII.1. Theoretical Results for Front Impact of the Chassis

Material

Deformation

(mm)

SAE AISI 4130 Carbon steel 3.725



A. 8.2. Theoretical Results for Rear Impact of the Chassis

B.

Material

Deformation

(mm)




C. 8.3. Theoretical Results for Side Impact of the Chassis

D.

Material

Deformation

(mm)




E. 8.4.FEA (Ansys) Results for Front Impact of the Chassis

Material Von Mises Stress (MPa) Deformation (mm)

SAE AISI 4130 Carbon steel 470.31 3.588





F. 8.5.FEA (Ansys) Results for Rear Impact of the Chassis

G.


SAE AISI 4130 Carbon steel 437 4.191



H.

I. 8.6. FEA (Ansys) Results for Side Impact of the Chassis

J.





IX. CONCLUSIONS

The main aim of the project was to design a car for the SAE Supra 2016.But for designing a

chassis we have to consider it under various parameters to determine whether this chassis can

withstand all the forces acting on it or not. There are two ways of analysis of chassis frame one is

physical mode another is software mode. The physical mode is not economical therefore we have

done the analysis only in software mode. The various analysis is done on Ansys software. The

materials SAE AISI 4130 Carbon steel, SAE AISI 1020 Carbon steel, and SAE AISI 4027 Carbon

steel were compared with each other. The results obtained of SAE AISI 1020 and SAE AISI 4130

shows almost same deformation and stresses as of AISI 4130 Carbon steel which is a recommended

material for chassis building by Supra rulebook. So taking this very small change in account we can

say that SAE AISI 1020 Carbon steel or SAE AISI 4027 Carbon steel can be used in place of AISI

4130 Carbon steel as they both are cheaper than the first’s. But by taking cost as the dominating

issue we can say that SAE AISI 4027 Carbon steel is the most suitable material for building a SAE

Supra race car space frame chassis.

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Science and Innovative Technology, ISSN: 2319-5967, Volume 5, Issue 1, January 2016.

2. Chartree Sithananun,,Nuksit Noomwongs, “SAE Student Formula Space Frame Design and Fabrication”, The

Second TSME International Conference on Mechanical Engineering 19-21 October, 2011, Krabi .

3. N. G. Jogi, Akshay P. Take, Yogesh Asolkar, Sheikh M Aftab, “Review work on analysis of F1 car frame using

Ansys”, IJRET , Apr-2014 .

4. G.Guru Mahesh,"Design and analysis of a single seater race car chassis"ISSN 2014.

5. Micheal broad, “design development and analysis of SCSHFH.09 chassis”,2009 SAE International.

6. Ravinder Pal Singh, “Structural performance analysis of formula sae car”, Jurnal Mekanikal December 2010, No. 31,

46 - 61.

7. Abhijit Das, “Design of student formula race car chassis”,IJRET-2015

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