Design and Analysis of Light Weight Formula SAE

Chassis and Attenuator

Student's Name Mohammedarif I. Doddamani AE (FT-2015)

Academic
Monish Gowda M. H. and Hima Kiran Vithal V.
Supervisor(s) Mohammedarif I. Doddamani
Industrial mdarif.mech@gmail.com
Ph. No: 0 81237 23118
Supervisor(s)

Keywords: Formula SAE, Chassis Design, Attenuator, Static Structural Analysis, Crash Analysis

Abstract:
Formula SAE is a competition organized by SAE International. Students from various colleges across the world
participate in formula style race car competition. Each student team will build a prototype of race car and the winners
are judged in number of events like design, cost and manufacturing analysis, presentation, acceleration, skid pad,
autocross, fuel economy and endurance event. Hence for a team to perform better in most of these events vehicle
mass has to be reduced and to provide safety to the driver vehicle crashworthiness has to be improved. In the present
dissertation work design and analyses of an Formula SAE chassis is carried out with a goal of achieving lightweight
chassis and improving crashworthiness of the vehicle.
The CAD model of available chassis is created. The required modification of the chassis has been done as per the SAE
guidelines. Structural analysis has been carried out using steel, aluminium and aluminium alloy chassis. Aluminium
alloy was finally selected chassis material for the FSAE vehicle. Crash analysis has been performed using aluminium
alloy chassis. The crash analysis was performed for the chassis with and without honeycomb attenuator. Finally,
aluminium alloy chassis with Honeycomb attenuator design was selected for chassis structure with a goal of achieving
lightweight chassis and improving crashworthiness of the vehicle.

Conclusion: Weight of the chassis has been reduced from 124.6 kg to 41.74 kg by using aluminium alloy structure.
66.5 % of weight reduction is achieved when compared to steel structure. The energy absorbed by chassis without
attenuator is 39 kJ and energy absorbed by the chassis with honeycomb attenuator is 115kJ. By using honeycomb
attenuator energy absorbsion has been improved.

Book of Abstracts 32 November 2017