The goal of this design project is to design, analyze, and manufacture a chassis for the University of Delaware FSAE team. Through extensive. Designing and constructing a chassis and suspension system for a Formula SAE racecar is a highly complex task involving the interaction of hundreds of parts. PDF | On Oct 25, , Lucas Iensen Bortoluzzi and others published Formula SAE Chassis Design to Improve Suspension Tuning.

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You’ll be much happier having a heavy car that completes all the event, than a “light” one that has the wheels fall off.

Designing an FSAE chassis –

Designing a chassis Post by marcush. Home Forum Automotive Other racing series. The engine block mass attached to the mounts. Post here to have your team’s flair added to the lis. I almost lost two days of work last year, and we recovered the data in less than one hour thanks to the automatic copies.

Design and optimization of a Formula SAE racecar chassis and suspension

You do not need to simulate the front impact load case for a SES frame, but it can be an interesting test. Want to add to the discussion?

I’m leaving composites out of the picture for now, I have to work with the steel tubes we have in our lab. Start by learning T 3 really really well.

Ultimately it seemed obvious to fix it at nodes in the main hoop or at nodes in the very rear of the frame main hoop bracing supports maybe because it would give my a more realistic result. Examples of the easy decisions: Also would recommend a seperate suspension tab jig. Purchase paper copies of MIT theses.

You are not designing to any crash loading cases.

Does the front wheel see positive camber from pickup point deflection when turning? Also would recommend a seperate suspension tab jig There will be iterative design around suspension, engine mounts, and driver position.

Dfsign in mind the rules exist for safety, and a chazsis playing field, they are not guidelines for performance I read a neat SAE paper where they compared cornering performance to torsion stiffness.


For what it’s worth, I’ve done a front bulkhead and supports to the rule minimum tubing and plate thickness without issue Focus your stress analysis on deflection. This thesis examines the critical factors in designing and implementing a Formula SAE chassis from the ground up, with a focus on the performance and optimization of the vehicle as an entire system rather than a collection of individual parts.

Massachusetts Institute of Technology. You’re right in that a good chassis makes for a good starting point. First of all decide if you want to build a composite chassis or a steel frame. Some features of this site may not work without it. But that’s probably the easier part. Ironically, I was probably in the safest position because I was strapped in the car So many teams fail at this.

It’s really easy to do and we’ve done it using 2×4’s and cardboard, but if you skip this step you seriously risk building an uncomfortable car. I would come up with a deslgn chassis concepts with regards to how tubes are routed then determine how much each concept flexes for a given loading scenario.

We had that happen to our first car during testing for our second car and we were lucky no one got hurt. Another thing, do you guys recommend any certain software for chassis design?


You would find out if the engine mounts break and dump a block in the drivers back though. I’m currently working on the chassis design and was wondering, what are the major the design criteria that go into designing the chassis apart from the FSAE regulations of course.

IMO if a first year car can finish and score in all the events then regardless where you finish its a win in itself. As others said, connect the dots, and read the rules.

The reverse can also be successful – design with ultimate reliability as primary and loss of performance as the risk, then reiterate to improve performance using analysis FMEA can be used since extreme lack of performance is a “failure mode” of a race car AF is largely unpopular; I think only 2 teams submitted intents for Michigan this year and they have been notified for the future.


Just functional, and it has to WORK. Your due diligence for crash safety is achieved by meeting the chassis rules. I just don’t understand well about where the frame would be fixed so I can conduct the simulation of the front impact I’m using solidworks. And besides, FSAE regulation have quite some restrictions on use of composite materials, so that will have to be kept in mind as well.

There’s nothing easier than over-designing the chassis and making it weigh a tonne, but that’s not my goal, not on a race car at least. But I was hoping for a well engineered chassis since it will be used for the next years to come, a good “base” sort of thing, rather than having it as a first item on next year’s upgrades list.

Make the steering axis go through the center of the tire contact patch. Hello again, I just wanna ask another question about assumptions regarding stress analysis. The FSAE advice facebook group is good for getting more than one response though, and I chassi some judges read through it as well. Designing and constructing a chassis and suspension system for a Formula SAE racecar is a highly complex task involving the interaction of hundreds of fsas that all perform an essential function.

Then doing design iterations of course to try and achieve the lowest CG point possible.

I’m familiar with FSAE michigan tech and rules in particular, but the rules should be similar. Your fsaee diligence for crash safety is achieved by meeting the chassis rules Torsion stiffness and other parameters are relevant for how your car handles, and for design judging. Decide what rims and tires you’ll use, then design a suspension based on those wheels. Personally I think you can do a lot of thinking but without actually put your hands on something you can’t tell where your practical limit is.

Know what you need, and desihn what can be made 6 Build.