Chassis design and manufacture for the formula-SAE competition

Campbell, James Fleming (2001). Chassis design and manufacture for the formula-SAE competition B.Sc Thesis, School of Engineering, The University of Queensland.

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Author Campbell, James Fleming
Thesis Title Chassis design and manufacture for the formula-SAE competition
School, Centre or Institute School of Engineering
Institution The University of Queensland
Publication date 2001
Thesis type B.Sc Thesis
Supervisor Professor Hal Gurgenci
Total pages 129
Language eng
Subjects 09 Engineering
Formatted abstract

This thesis aims to conceive, design, analyse, and manufacture a small formula style racecar’s chassis for the Formula-SAE competition run by the Society of Automotive Engineers.

Comprehensive researching enabled the different kinds of vehicle chassis to be compared and contrasted and the specific qualities, performance, cost and material requirements of each type. The associated manufacturing techniques were also heavily researched and scrutinised for their appropriateness and cost efficiency for the construction of the chassis.

A steel space frame was selected, as it possessed the best balance of performance, cost, reliability and ease of manufacture of the different frames researched. Armed with restrictions set by the competition’s rules and requirements from several sources, the iterative process of design began. A computer design was produced using the 3-D solid modelling package, Solid Edge, and several small prototype models and fullscale sections of the chassis were built for testing factors such as driver ergonomics and member layout.

With a completed chassis layout decided upon, Finite Element Analysis was carried out on the design using Strand 7. This was done to optimise the performance of the car in terms of its weight, strength, stiffness, and fatigue properties.

The design of a construction order and actual fabrication of the chassis was carried out by the author. During the fabrication of the chassis many unforseen problems were encountered, though all were eventually overcome.

Due to unforseen time constraints, the scheduled testing of the chassis will not be completed before this thesis is published. However, post manufacture inspection indicates that the chassis was built to the highest standard and exceeds all requirements and restrictions that were set at the beginning of the design process.

Keyword Chassis design
Chassis manufacture
Formula-SAE competition
Additional Notes * Mechanical Engineering undergraduate theses. 2001

Document type: Thesis
Collection: UQ Theses (non-RHD) - UQ staff and students only
Citation counts: Google Scholar Search Google Scholar
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