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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As mentioned previously, a lot of the nodes on the chassis are “pre-designed” by placement of the major components. I would come up with a couple chassis concepts with regards to how tubes are routed then determine how much each concept flexes for a given loading scenario. Decide what rims and tires you’ll use, then design a suspension based fsaae those wheels. If your frame is a wet noodle, but still meets the rules, you can drive in endurance.

No worries, they are good questions.

Also, last thing to keep in mind is that the chassis is the lowest priority item. The thesis will serve as a summary of the knowledge that I have accumulated over four years of personally designing and overseeing the manufacturing of the MIT Motorsports suspension, provide insight into the design of the MY vehicle, and act as a guide for future chassis designers.

One big radius on top of main hoop top or 2 bends or 3? Become a Redditor and subscribe to one of thousands of communities. It’ll be as much of an desigj in car building as organization building. Everyone will be expected to follow section T of the rules.

Or will everyone be expected to adhere to the rules by the book? 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. Tom, quit board posting and go finish Your build blog. A lot of it should be literally connecting the dots, and keeping tubes where the rules allow.


You’ll be much happier having a heavy car that completes all the event, than a “light” one that has the wheels fall off. Additionally, many of the tube cross-sections edsign specified in the rules, so there is not a whole lot left for optimization, other than how you “connect the dots.

The reverse can also be successful – design with desiggn 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 I think it’ll be impractical unless you really have access to alot of resources and know-how, to design a ultimate performing car as a target.

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.

Our team decided to go Chassis first and now we’re either stuck with a 1. My question is that are the dssign for those tests given?

Design and optimization of a Formula SAE racecar chassis and suspension

chassid Adapt as you see fit. 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 chawsis on deflection.

Your dsae diligence for crash safety is achieved by meeting the chassis rules. Yes, we are a rookie team, my school tried building ones in the past but never really worked out, I plan on getting the wheel going with this so fingers crossed. 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.

Then doing design iterations of course to try and achieve the lowest CG point possible. Use this accumulative deflection to see what it does to Your suspension geometry.

Keep in mind the rules exist for safety, and a level playing field, they are not guidelines for performance.

Use a lot of jigs when you make things chassie you make them right, and once the car is done drive the crap out of it A more realistic method is fixturing the frame anywhere away from where you are concerned with stress. Most FSAE teams choose the latter but often lack the scientific approach of what to improve.


Its so easy, even for an established team, to overthink and take on way too more than it can manage. Make sure the driver can reach everything and their helmet is inside the roll hoops. Also i would like to suggest do ergonomics test. Only then can you begin to make Chassis. Impact is a chassiis case for fixturing, because in reality the fixture is inertia.

Your due 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. Issue with one of the dates? As others said, connect the dots, and read the rules.

Examples of the easy decisions:. All opinions are my own and not those of current or previous employers. Composites is quite complex and you will simply shoot yourself in the foot with that deisgn you are bringing an car on track wich you do not fully understand, thus you cannot max the performance of the car. Hey everybody, My team and I are currently beginning the design process for our Chassis. AF is largely unpopular; I think only 2 teams submitted intents for Michigan this year and they have been notified for the future.

Designing an FSAE chassis –

Oh, and having a wheel fly off is not only embarrassing, it can also be dangerous. For what it’s worth, I’ve done a front bulkhead and supports to the rule minimum tubing and plate thickness without issue. Massachusetts Institute of Technology.

Apply these loads along the correct direction to the correct nodes, and evaluate what your chassis deflections mean for vehicle dynamics.