DESIGN AND MANUFACTURING OF CHASSIS

OF A PROTOTYPE VEHICLE
PRESENTED BY:
ABDUL AHAD ANWAR
ASIM RIAZ
BSME(14-18)

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 OUTLINE
• SHELL ECO MARATHON (SEM)
• PROTOTYPE VEHICLE
• PROBLEM STATEMENT & AIM
• CHASSIS DESIGN CONCEPTS
• DESIGN PROCESS
• MANUFACTURING

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 SHELL ECO MARATHON(SEM)
• Shell Eco Marathon Competition
• SEM Asia
• PIEAS and SEM Asia

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 Shell Eco Marathon
Vehicle Categories:
• Energy Based
• Concept Based

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 Prototype Vehicle
• A prototype is a vehicle made
to show off new developments.

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 Problem Statement & Aims
• High weight of previous chassis
• Design lightweight chassis

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 Chassis Design Concepts
• Chassis: A chassis is the framework that
a vehicle is built on.

Types:
• Space frame
• Ladder frame
• Monocoque

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Global Vehicle Loads

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 DESIGN PROCESS
• Material selection
• Design constraints
• 3D Modelling
• Simulation
• Results & Discussion

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Material Comparison

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 AL 6061 T6
Physical Properties Metric English

Density 2.7 g/cc 0.0975 lb/in³

Mechanical Properties

Hardness, Brinell 95 95
Hardness, Knoop 120 120
Hardness, Rockwell A 40 40
Hardness, Rockwell B 60 60
Hardness, Vickers 107 107
Ultimate Tensile Strength 310 MPa 45000 psi
Tensile Yield Strength 276 MPa 40000 psi
Elongation at Break 12 % 12 %
Elongation at Break 17 % 17 %
Modulus of Elasticity 68.9 GPa 10000 ksi

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 Member Profile
• Circular vs Square Profile
• Circular section:I=h^4/4π=h4/12.57
• Square section: I=h^4/12
• Therefore,we choose square cross
section.

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 Number of Wheels
4 wheel design is realistic but has the following demerits
• Increases the weight and complexity. Requires a suspension
system to compensate for the unevenness of the track in order
to maintain the tire/road contact.
• A differential is required in order to balance drive torque
on the rear wheels.
• It can be concluded that the best setup for a fuel efficiency
challenge is the three wheeled setup.

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 3D Modelling

• Solidworks 2017

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 Design Iterations

Iteration 2
Iteration 1

Iteration 3 Iteration 4

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 Final design selection
Iteration No Profile Weight(kg) Deflection(mm) Factor of Safety
1 Circular (1.5 in 10.16 3.8 2.3
dia,1.5mm thick)
2 Square 7.30 6.4 1.2
(1.5*1.5in,3mm
thick)
3 Square(1*1 in,1mm 4.5 5.4 1.4
thick)
4 Square(1*1 in,1mm 5.1 4.6 1.5
thick)

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 Meeting the Design constraints

• Height 52cm
• Width 70cm
• Length 335cm
• Track Width 62cm
• Height:Track Width ratio <1.25
• Wheelbase 254cm
• Driver weight 50kg
• Vehicle weight 27kg

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 Simulation
• ANSYS 17.1
• Solidworks 2017

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 Design Constraints
• SEM 2018 Rules
Chapter 1
• Max. Static Load 700N
From any direction

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RESULTS

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 RESULTS
• ANSYS a useful tool
• Not a Blackbox
• Mass = 4.54 kg as per Solidworks
• Welded Mass = .48kg as per Solidworks

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 Manufacturing
• Filler rods : ER5356

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 Future Prospects

• Our design and outlook will further help to have a basic

guideline on future teams in PIEAS.

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 THANKYOU!

• ANY QUESTIONS?

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