Transcript 2013 FSAE Chassis Poster

Overview and Scope
Drivetrain, Powertrain
Final Design
 Design and fabricate a stiff and
lightweight tube-frame chassis
 Completely original design with
emphasis on:
• Weight loss
• Split-chassis design
• Sub-system integration
• Aesthetic appeal
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Design and fabricate drivetrain mounting
Design and fabricate engine mounts
Design for exhaust and intake clearances
Design for appropriate chain clearances 𝑘
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Constraints
 Compliance with 2014 FSAE rules
Split Assembly
2012-2013 Chassis
 ½” Bolts in double
shear
 Extra long weld
and gusset areas
designed to
strengthen joint
 Sleeved for
compressive
strength
Weight Loss
 Large, heavy
• 115 lbs
 Extra nodes, thick tubing
Key Metrics
Metrics
Weight
(including bracing, tabs,
mounts, and gussets)
Target Value
65lb
Acceptable
Value
85lb
Vertical Center of Mass
12 in
13.5in
Cost
$950
$1900
 71 lbs
 Thin wall
(0.028”) tubing
 Strategically
placed nodes
Manufacturing
 Tube prep
• Rough cut with
miter saw
• Final cut on lathe
• Bend tube if
necessary
• Notch on lathe
with hole saw
• Polish and clean
tube for welding
• Tack structure
together
 Assembly
• Tack
subassemblies
together
• Double-check
manufactured
tolerances
• Final weld (TIG)
Final Drivetrain Design
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Chain tensioned by turnbuckles
Turnbuckles in tension
Pivots about bottom pinned joint
Factor of Safety of 4
Clearances optimized using CAD
Cost
Description
Item
Quantity
Base Price
Total Price
Main & Front Hoop Members
4130 Round Seamless Chromoly Steel, 1" x 0.095"
40
3.43
137.2
Bracing Members
4130 Round Seamless Chromoly Steel, 1" x 0.065"
40
2.65
106
Support Members
4130 Round Seamless Chromoly Steel, 1" x 0.028”
60
Donated
0
Extra Support Members
4130 Round Seamless Chromoly Steel, 1" x 0.049“
116
2.23
258.68
Suspension Support Members
4130 Square Chromoly 1"x 1"x 0.049"
24
9.92
238.08
Tube Sleeves
4130 Round Seamless Chromoly Steel, 1.125" x 0.058"
3
4.66
13.98
Welding Filler
TIG Filler Rod
3
10.90
32.70
Impact Attenuator Plate
Steel Sheet, 0.060" x 12" x 24"
1
16.71
16.71
Drivetrain Uprights
6061 Aluminum 3/4“ x 6“ x 36"
1
100.24
100.24
Mounting Tabs
Tabs for drivetrain, split, gussets
26
Student Shop
0
TOTAL
$904