2. Frame Design
• The 2016-2017 Frame was designed through
the use of SolidWorks
• A tubular space frame design was picked due
to its ease of manufacturability
• The newer design main focus is toward
greater accessibility to the drivetrain
packaging
3. FEA Testing
• An initial FEA tests was performed on
SolidWorks to get a general understanding
behind the frame’s torsional rigidity
• The rear suspension mounts were fixed, while a
150 lbf was applied to the front suspension
points
• The main goal of the FEA was to prove and
validate a frame stiffness which is about 8x the
roll-over stiffness
• Stiffness goal of 1500 lb-ft/deg was set, while a
1350 lb-ft/deg was achieved through FEA
4. Manufacturing Process
• A multi-plate jig system was used to position the frame
members for welding
• The method was used due to its ease of manufacturability
and lower overall cost compared to a modular jig system
• Plates were setup at certain (pre-set) positions for spot
welding
• After which the overall structure was TIG welded
5. Torsional Rigidity Test
• To further validate the new frame, a physical
torsional test was performed to compare the
FEA data to real life results
• The rear suspension points were fixed by
attaching the suspension points to a
stationary jig
• A bar was attached to the front suspension
rail, and a force of 150 lbf was applied on
either side in a torsional manner
• The deflection was measured by the use of
dial indicators which were setup at multiple
locations across the frame
• A torsional stiffness of 1389 lb-ft/deg was
measured which confirms our earlier FEA test
result of 1350 lb-ft/deg
6. Dynamic Testing
• Please use the attached link for video regarding Dynamic
testing
• https://www.youtube.com/watch?v=XxEFc2eMtWY
• Strain gauges and accelerometers are used to gather data
regarding frame and suspension
• Corrective measures and alterations are to be made
based on data gathered through testing
