Abstract:
This study focuses on the structural assessment and optimization of a student formula car’s space tubular frame, which serves as the vehicle’s foundation, balancing strength with lightweight design to ensure optimal performance. The primary objective of the research is to identify the best material and maximize the frame’s torque-handling capacity to improve the car’s performance under various racing conditions. Using advanced simulation tools such as ANSYS for structural analysis and CATIA for geometry modeling, the study evaluates the frame’s behavior under different loading scenarios, including deformation, stress, strain, and twist angles. A key aspect of the research is the incorporation of topological optimization, which aims to reduce the frame’s weight while maintaining sufficient strength and stability for the demands of competitive racing. This approach enables the design of a frame that is not only strong enough to handle the stresses encountered during high-torque conditions but also light enough to improve the vehicle’s overall efficiency.
The study’s findings reveal critical insights into the frame’s performance under real-world racing conditions, with simulations indicating that stresses and deformations increase linearly with the applied torque. This reinforces the importance of selecting the right torque limit to maintain structural integrity and prevent failure. The research highlights the superior performance of Steel SAE 1040 (Cold Drawn) when compared to aluminum alloys, as it offers better resistance to deformation, strain, and twist angles. The optimized design, achieved through topology optimization, reduces the overall mass of the frame by 20% while maintaining critical load-bearing components, thus enhancing the vehicle’s overall performance without compromising structural strength. The study concludes that Steel SAE 1040 is the optimal material choice due to its excellent strength-to-weight ratio, providing valuable insights for improving the design of future racing vehicles and laying a foundation for further advancements in racing frame engineering.
Aim:
The objective of this study is to enhance the torsional strength of a student Formula Race Car chassis by applying topology optimization techniques to a tubular space frame design. By leveraging advanced material distribution optimization, the aim is to create a chassis that maintains a balance between lightweight construction and structural integrity. The process involves identifying the optimal arrangement of materials to improve the chassis’s ability to resist torsional forces without adding unnecessary weight. Using Finite Element Analysis (FEA) techniques, the chassis design is subjected to performance verification under simulated real-world conditions, ensuring that it meets the required strength and durability standards for racing. This optimization approach aims to produce a frame that not only offers superior strength but also contributes to overall vehicle efficiency, ensuring both performance and longevity while reducing the overall mass of the chassis.
Objectives.
This study aims to optimize the design of a Formula Student chassis by determining the accurate dimensions and material selection to meet both structural and performance requirements while adhering to Formula Student guidelines. The process begins with design calculations to ensure that tube sizes satisfy strength, safety, and lightweight criteria. A comprehensive 3D model of the space frame chassis will be created using CAD software, capturing all critical tube connections, nodes, and geometry essential to the vehicle’s performance, facilitating accurate draughting for manufacturing. The chassis will then undergo Finite Element Analysis (FEA) simulations to evaluate its structural behavior under torsional loads, assessing key factors such as stiffness, deformation, and stress distribution to guide necessary design modifications for improved safety and performance. To further enhance efficiency, topology optimization will be applied to reduce weight by identifying areas where material can be eliminated without compromising structural integrity. Finally, the selection of the ideal material will be based on a thorough evaluation of factors like durability, strength, fatigue resistance, and manufacturability, ensuring the chassis is both robust and lightweight to withstand the rigors of competitive racing.
