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Chassis

The chassis is essentially the backbone of the car. All components and loads must be attached to the chassis. Chassis design also affects the overall look and feel of the car as it is typically the first thing to be noticed. We currently use a steel tube frame chassis.

What We Do

This subsystem is tasked to design, develop, build, and validate the chassis of the car. For a racing chassis to be effective, it must balance structural rigidity with a lightweight and aerodynamically efficient design. We do a significant amount of CAD design, analysis, and physical validation to ensure this outcome. We also work closely with other systems, such as suspension and powertrain, to accommodate and create any applicable mounting or packaging needs.

History

Since the beginning of GTMS, our chassis has always been comprised of a steel tubing space frame. The first year for a composite chassis design was 2017, which effectively lessened the weight of the car by approximately 7 pounds. This upcoming competition year will provide the opportunity to develop influential change in the car’s design and further promote weight reduction.

Technical Information

Chassis design must take into account desired stiffness, structural strength, center of gravity, weight, manufacturability, and ergonomics. The book, Design of a Formula Student Racecar Chassis, has great in-depth information on these components, along with material specifications and benefits.

Currently, the car’s chassis is comprised of ⅔ composite “monocoque” and ⅓ steel tube space frame. The two are manufactured separately and mated together. We make the steel chassis in-house. All tubes are welded together, and the frame is typically shipped out for powder coating.

The monocoque requires several phases of composite work. A plug in the shape of the desired design is machined, sanded, and prepared to lay up the mold for the monocoque. Once the mold has cured, the monocoque itself is laid up based on a predetermined ply schedule, which is designed to maximize the strength of the chassis by offsetting weave patterns, thereby preventing shearing. It is a carbon sandwich structure, with about 7 layers of carbon on the inside and outside, and an aluminum Flex-Core in the middle. The monocoque is completed with the help of Delta Tech-Ops, the airline’s facility at the Atlanta airport, as we use their autoclave for our composite work.

Future Goals and Projects

We are looking to improve the geometry of the monocoque, lower the nose to lower the CG (center of gravity) height, and give the driver better visibility. Our ultimate goal is, of course, to complete a full monocoque.