This document summarizes the design and structural analysis of a racing car chassis. It describes using CATIA software to model the chassis and ANSYS for finite element analysis to simulate various loads on the chassis, including front impact, side impact, torsion, bumps, and rollovers. The analysis found maximum deformations between 1-5 mm and stresses below 300 MPa across the tests, with safety factors above 1.5 in all cases. The document concludes the finite element analysis provided valuable insights for designing a chassis that can withstand the forces of racing.

1. DESIGN & STRUCTURAL PERFORMANCE ANALYSIS
OF SUPRA SAE CAR CHASSIS
PREPARED BY: UNDER THE GUIDANCE OF:
PRASHANT SAHGAL ER. RAMENDRA SINGH NIRANJAN
B.TECH (4rth Year) H.O.D
(MECHANICAL ENGINEERING) DEPT. OF MECHANICAL ENGINEERING
U.I.E.T C.S.J.M UNIVERSITY KANPUR

2. DESIGN OBJECTIVES
 Research fundamentals behind designing a space frame that will see
forces associated with a race car (COMPLETED).
 Research chassis materials that can withstand the high performance
ratings of a formula style race car (COMPLETED).
 Design a chassis that will be able to withstand the loads from static
forces using solid modeling software.
 Perform static load analysis using finite element analysis software.

3. COMPUTER AIDED ENGINEERING
CATIA & ANSYS
 Computer-aided engineering (CAE) is the broad usage of computer software to aid in
engineering analysis tasks. It includes Finite Element Analysis (FEA), Computational Fluid
Dynamics (CFD), Multibody dynamics (MBD), and optimization.
 CATIA (Computer Aided Three-dimensional Interactive Application) is a multi-platform
CAD/CAM/CAE commercial software suite developed by the French company Dassault
Systèmes. Written in the C++ programming language.
 ANSYS Mechanical software is a comprehensive FEA analysis (finite element) tool for
structural analysis, including linear, nonlinear and dynamic studies. The engineering
simulation product provides a complete set of elements behavior, material models and
equation solvers for a wide range of mechanical design problems.

4. CAE IN AUTOMOTIVE INDUSTRY
 CAE tools are very widely used in the automotive industry.
 Reduce product development cost and time.
 Improving the safety, comfort, and durability of the vehicles.
 Design verification is now done using computer simulations
rather than physical prototype testing.
 Audi R8 is designed on CATIA V5.
 Several MNC’s like BMW, Mercedes Benz, TATA Motors,
Mahindra & Mahindra also uses these CAE software (CATIA
specially).

5. FRAME NOMENCLATURE
 Main Roll Hoop
 Front Hoop Bracing
 Front Bulk head
 Front bulkhead Support
 Front Roll Hoop
 Main Hoop Bracing
 Side Impact Structure

6. BASIC RULES FOR FRAME APPROVAL
To get a frame approved at Technical Inspection:
 Minimum tube size, 1.00inch OD x 0.049 inch wall
(25.0 mm x 1.2 mm metric)
 Triangulation
 No bent tubes (other than Main Hoop and Front Hoop)
 Loads from Mandated Tubes go to Structural Nodes.

7. DESIGN PROCESS
 Basic Hand Sketching
 Sketch Drafting on Chart Paper
 Modelling in CATIA V5
 Finite Element Modelling in ANSYS 14.5
 Analyzing the Model in ANSYS 14.5
 Optimize the Model according to the
results obtained
 Re-modelling of the Improved model in
CATIA V5
 Drafting the Improved Model

8. GENERAL REQUIREMENTS
 Main & Front Roll Hoop
 Main Hoop Bracing
 Frontal Impact Structure
 Bulkhead
 Side Impact Structure
 Cockpit

9.  Mesh Element – Pipe 289
 Element Size – 10mm
 Quality – High
 Number of Elements – 5573
 Number of Nodes – 11073

10. FRONT ANALYSIS
 A vehicle moving with a velocity of 100kmph
(27.78m/s) and rams into the stationary
mass longitudinally. (WORST CASE)
 According to research, impact time is taken
0.15 seconds.
 Mass of the Vehicle is taken approximately
300kg.
 Load of 55560N corresponding to the
deceleration value of 18.52g acting
longitudinally on the front bulkhead of the
frame at two keypoints.

11.  Maximum Deformation is 0.91437mm.
 Von Mises stress is 113.206MPa.
 The Factor of Safety is 3.84

12. SIDE IMPACT
 The vehicle gets hit from one side of the
frame
 The deceleration value for side impact is
3g (9000N approx.)
 Fixing lower points of the front
suspension in all the directions
 Fixing lower rear suspension points in all
the directions

13.  Maximum deformation is 4.98647mm.
 Von Mises Stress recorded is
287.802MPa.
 The factor of safety for the frame is
1.51

14. TORSIONAL ANALYSIS
 The vehicle traverses on an uneven
road.
 The two tyres on the front axle
experience a moment.
 NO CONSTRAINT at the front
suspension points.
 Fixed all rear suspension points in all
directions.
 Load of equal magnitude 3g (9000N)
but opposite in direction is applied on
front suspension points.

15.  deformation of 4.59129mm.
 Von Mises Stress is recorded
as 259.805MPa.
 factor of safety for the frame is
1.67

16. BUMP ANALYSIS
 The suspension system are
compressed to its maximum extent
and act like solid member of the
vehicle.
 Load is transferred to the roll cage
members of the vehicle.
 NO CONSTRAINTS on the front
suspension points.
 Vertically upward load of magnitude
3g (9000N approx.) at 8 nodes of the
front suspension points in the frame.

17.  The deformation of 4.82954mm.
 Von Mises Stress is recorded as 220.641
MPa.
 Factor of Safety for the frame is 1.97

18. ROLL OVER ANALYSIS
 The vehicle topples down from a
slope with an angle of 45°.
 The upper and rear members of the
vehicle will bear the force.
 Load of magnitude 3g (9000N
approx.) at the 4 nodes is applied
inclined at an angle of 45°.
 Fix front suspension points(lower) in
y-direction only.
 Fix rear suspension points (lower) in
all direction

19.  Deformation is 1.0922mm.
 Von Mises Stress is recorded as
73.9179MPa.
 Factor of Safety for the frame is 5.88

20. RESULTS & CONCLUSION
 Stress plots and deformations of critical elements undergoing different loads during the tests
were analyzed using ANSYS.
 The use of finite element analysis was invaluable to the design and analysis of the frame for
SUPRA SAE FORMULA ONE vehicle.
 In future work on this project we could perform and demonstrate the Dynamic Analysis by
using CAE software called LS-DYNA.
 Fabrication of the model.
Type Of Impact
Test
Loading Force
(N)
Number Of
Nodes
Maximum
Deformation
(mm)
Von Mises
Stress
(MPa)
Factor Of
Safety
Front 55560 2 0.91437 113.21 3.84
Side 9000 3 4.98647 287.80 1.51
Torsional 9000 8 4.59129 259.80 1.67
Bump 9000 8 4.82954 220.64 1.97
Roll Over 9000 4 1.0122 73.92 5.88