Chassis Design for SAE Racer
University of Southern Queensland Faculty of Engineering and Surveying Chassis Design for SAE Racer A dissertation submitted by: Anthony M O’Neill In fulfilment of the requirements of ENG 4111/2 Research Project Towards the degree of Bachelor of Engineering (Mechanical) Submitted: October 2005 1 Abstract This dissertation concerns the design and construction of a chassis for the Formula SAE-Aust race vehicle – to be entered by the Motorsport Team of the University of Southern Queensland. The chassis chosen was the space frame – this was selected over the platform and unitary styles due to ease of manufacture, strength, reliability and cost. A platform chassis can be very strong, but at the penalty of excessive weight. The unitary chassis / body is very expensive to set up, and is generally used for large production runs or Formula 1 style vehicles. The space frame is simple to design and easy to fabricate – requiring only the skills and equipment found in a normal small engineering / welding workshop. The choice of material from which to make the space frame was from plain low carbon steel, AISI-SAE 4130 (‘chrome-moly’) or aluminium. The aluminium, though light, suffered from potential fatigue problems, and required precise heat / aging treatment after welding. The SAE 4130, though strong, is very expensive and also required proper heat treatment after welding, lest the joints be brittle. The plain low carbon steel met the structural requirements, did not need any heat treatments, and had the very real benefits of a low price and ready availability. It was also very economical to purchase in ERW (electric resistance welded) form, though CDS (cold drawn seamless) or DOM (drawn over mandrel) would have been preferable – though, unfortunately, much more expensive.
[Show full text]