The document describes the design of a Formula 1000 racing chassis. Formula 1000 is an amateur racing class that uses a 1000cc motorcycle engine. The chassis must be made of steel and weigh at least 1000 pounds. The document discusses the design of the team's steel tube space frame chassis, which uses Pratt & Town's lattice trusses. It provides cost estimates for materials and construction labor. Simulation testing analyzed stresses on the frame from rollovers and impacts from other cars at 60 mph. The simulations found maximum displacements of less than 7 inches, meeting requirements.

1. Formula 1000 Frame Design Kimo “Kokonuts” Spector David “Deuce” McMahon Matthew “McLovin” Diasio Tomas “T-Bird” Lafferriere Daniel “Fat Dan” Rist

2. Formula 1000 Class Closest amateur competition to Formula One Single-person, Open-wheel, Open-cockpit design Powered by a 1000cc motorcycle engine Chassis must be made of steel Minimum racing weight of 1000 lbs. Governed by the SCCA (Sports Car Club of America)

3. Chassis Design Monocoque design were used through 1950’s Space Frame began growing in popularity in late 1960’s Space Frame a low cost, lightweight, easy to maintain chassis Now used mainly in Amateur Racing

4. Our Chassis Steel tube space frame design Tube size specified by SCCA rulebook (AISI 4130) Raised nose design for improved aerodynamics Allows for the use of a full width wing Comprised of Pratt & Town’s lattice trusses

5. 3D Frame Model

6. Cost of Materials AISI 4130 is standard material for automotive frames Approximately $8 per foot SolidWorks gives frame volume Need to find length Divided volume by cross-sectional area of tube 177.8 ft of tube = $1,422.40 per chassis

7. Other Cost Factors Welding $75 per hour 40 man-hours to complete $3000 for labor per chassis Worst-case scenario: need 12 frames a year Assume that team orders 185 ft of tube per chassis (materials cost $1,480 per chassis) $53,760 to make 12 chassis a year

8. Testing Parameters First test was simulated rollover onto main hoop Other tests simulated impact with another F1000 car from various angles Weight assumed to be minimized to 1000 lbs Speed of 60 mph consistent with corner exit speed of a F1000 car Used a collision time of 0.1 seconds Used time derivative change in momentum to calculate equivalent force

9. Inconsistencies Simulates direct impact on frame Body would absorb some of impact Used fixed geometry restraints at wheel attachments Impacts would cause the car to slide Sliding would dissipate a great deal of the energy from the impact. Also assumes velocity of impacting car goes to zero, absolute worst case scenarios

10. Simulation Analysis Roll-bar test required by SCCA Frame experiences maximum displacement of .0855 in.

11. Stress Analysis Impact at cross point of cabin truss results in most displacement 6.664 in. of predicted displacement All other tests result in less than 1.6 in. of displacement

12. Stress Analysis Simulated front impact by removing first four fixed supports Deformation of less than an inch