Design and optimization of a Formula SAE racecar chassis and suspension

Abstract

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 that all perform an essential function. This thesis examines the critical factors in designing and implementing a Formula SAE chassis from the ground up, with a focus on the performance and optimization of the vehicle as an entire system rather than a collection of individual parts. Analysis includes examining the stiffness, strength, and weight of each part, as well as design verification. 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 MY2009 vehicle, and act as a guide for future chassis designers.