Design, manufacturing, and verification of a steel tube spaceframe chassis for Formula SAE

The Formula SAE chassis provides a number of functions: it protects the driver during high speed operation, links critical components such as the engine, drivetrain, and suspension together through a rigid structure, and distributes forces through the frame to allow for predictable handling and kinematics. This document examines and analyzes the critical factors in designing and building a Formula SAE chassis from 4130 chromoly steel tubing. The paper focuses on several main design issues and criteria, provides a detailed description of the manufacturing and jigging process, and also documents verification testing of the real chassis against the CAD and FEA models. The thesis will serve three functions: first as a summary of lessons I have learned about product development from personally overseeing the fabrication of the MIT Motorsports chassis for 3 years (MY2006 - MY2008), second as a guide for future generations of chassis engineers in frame design and construction, and third as a specific study and verification of the theoretical methods behind the current vehicle design.

Department dc:contributor.department

Massachusetts Institute of Technology. Dept. of Mechanical Engineering.

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2008

Author dc:creator

• Soo, Alexander M

Advisor dc:contributor.advisor

• Christopher L. Magee.

• Mechanical Engineering.

Statement dc:rights

• M.I.T. theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission. See provided URL for inquiries about permission.

Licence dc:rights.uri

• http://dspace.mit.edu/handle/1721.1/7582

Language dc:language.iso

eng

Handle dc:identifier.uri

http://hdl.handle.net/1721.1/45320

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/45320