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ABSTRACT

Design and Analysis of a race car chassis focuses on developing

a simple, lightweight and easily operated four wheel vehicle portion of
objectives. We considered the aspects of ergonomics, safety, ease of
manufacture and reliability incorporated them into the design
specifications. Analyses are conducted on all major components to
optimise strength and rigidity, improve vehicle performance and
reduce complexity and manufacturing costs
Roll cage was designed by giving high priority to driver
ergonomics, driver safety with reducing weight.An ergonomics
apparatus was designed and built to aid in the design of a Race Car
roll cage. The apparatus incorporated adjustable cockpit dimensions
that were adjusted accordingly for the tested subjects. A compilation
of this data was used to design a cockpit suitable for people within the
range of 95th percentile male and 5th percentile female.There after
roll cage was analysed for testing strength and deformation criteria
using ANSYS and final roll cage was fixed by the analysis data

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CHAPTER
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1

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CONTENTS

TITLE
INTRODUCTION
1.1 Background
1.2 Objective
1.3 Scope

Introduction
Terminology
Types of Chassis
Principle of chassis design

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CHASSIS LOADING
4.1 Types of Chassis Loading
4.2 Load Estimation
4.2 Chassis Stiffness Targets

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DESIGN METHODOLOGY
3.1 Design Procedure
3.2 Preliminary Objectives

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LITERATURE REVIEW
2.1
2.2
2.3
2.4

PAGE NO.

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ERGONOMICS
5.1 Ergonomics
5.2 Ergonomics Study Methodology
5.3 Chassis Layout and
Position Measurement

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SUSPENSION SYSTEM
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8

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SOLID MODELLING AND CHASSIS

COMPONENTS
7.1
7.2
7.3
7.4

Automotive Suspension System

Suspension Geometry Terms
Shock Absorber
Suspension Design Considerations
Design Methodology
Suspension Parameters
2D sketch of Suspension Design
ADAMS Analysis Data

Solid Modelling
Connecting Points
Analysis
Components of Chassis

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FINITE ELEMENT ANALYSIS

8.1 Design Optimisation
8.2 Results of Finite Element
Analysis for Chassis

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FINAL CAD MODEL

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CONCLUSION

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REFERENCES

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List of Tables
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Table 4.2.3: Approximate Masses of major components

Table 6.6.1: Suspension Parameters

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List of Figures
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Figure 2.3.1 Ladder chassis
Figure 2.3.2 Backbone chassis
Figure 2.3.3 Monocoque chassis
Figure 2.3.4 Space frame chassis
Figure 2.4.1 Torsional rigidity of a car chassis
Figure 2.4.2 The strategy on positioning space frame number
Figure 4.1.1 Longitudinal Torsion
Figure 4.1.2 Vertical Bending
Figure 4.1.3 Lateral Bending
Figure 4.1.4 Horizontal loosening
Figure 4.2.1 Force acting on a formula one car
Figure 4.2.2 Car side view with all parts
Figure 4.3.1 Tube in series
Figure 4.3.2 Linear to Torsion Spring
Figure 4.3.2 Vehicle Stick Model - Complaint Spring
Figure 4.3.3 Vehicle Stick Model Compliant Springs
Figure 4.4.1 Stiffness Graph
Figure 5.3.1 Photograph of Ergonomics Pattern
Figure 5.3.2 Elbow Angle Vs Height of drivers
Figure 5.3.3 Knee Angle Vs Height of the drivers
Figure 5.3.4 Heelstop Location
Figure 5.3.5 Depth Perception through Vision Depth Vs Height of the
drivers
Figure 5.3.6 Hand Height Vs Height
Figure 5.3.7 Headrest Location Vs Height

Figure 6.2.1.1 Caster Angle

Figure 6.2.2.1 Camber Angle
Figure 6.2.3.1 Kingpin Inclination and Scrub Radius
Figure 6.7.1 Two Dimensional Sketch of Front Suspension( In front
view)
Figure 6.7.2 Two Dimensional Sketch of Rear Suspension( In rear
view)
Figure 8.2.1.1 Front Impact-Stress Analysis
Figure 8.2.1.2 Front Impact-Deformation
Figure 8.2.2.1 Side Impact-Stress Analysis
Figure 8.2.2.2 Side Impact-Deformation
Figure 8.2.3.1 Rear Impact-Stress Analysis
Figure 8.2.3.2 Front Impact-Stress Analysis
Figure 8.2.4.1 Roll Over Test-Stress Analysis
Figure 8.2.4.2 Roll Over Test- Deformation
Figure 8.2.5.1 Torsion Test-Deformation
Figure 8.2.5.2 Torsion Test-Stress Analysis
Figure 9.1 Side View showing the orientation and spacing between
different roll hoops
Figure 9.2 Isometric view showing the orientation of roll hoops
Figure 9.3 Chassis Front View
Figure 9.4 Chassis Side View
Figure 9.5 Chassis Top View
Figure 9.6 Chassis Isometric View
Figure 9.7 Isometric View of Vehicle(Front)
Figure 9.8 Isometric View of Vehicle(Rear)
Figure 9.9 Side View of Vehicle
Figure 9.10 Rear View of Vehicle
Figure 9.11 Front View of Vehicle

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