Design, manufacturing, and verification of a steel tube spaceframe chassis for Formula SAE

Abstract

The Formula SAE chassis provides a number of functions: it protects the driver during high speed operation, links critical components such as the engine, drivetrain, and suspension together through a rigid structure, and distributes forces through the frame to allow for predictable handling and kinematics. This document examines and analyzes the critical factors in designing and building a Formula SAE chassis from 4130 chromoly steel tubing. The paper focuses on several main design issues and criteria, provides a detailed description of the manufacturing and jigging process, and also documents verification testing of the real chassis against the CAD and FEA models. The thesis will serve three functions: first as a summary of lessons I have learned about product development from personally overseeing the fabrication of the MIT Motorsports chassis for 3 years (MY2006 - MY2008), second as a guide for future generations of chassis engineers in frame design and construction, and third as a specific study and verification of the theoretical methods behind the current vehicle design.