College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
College - Author 4
College of Engineering
Department - Author 4
Mechanical Engineering Department
Degree - Author 4
BS in Mechanical Engineering
Date
8-2020
Primary Advisor
Joseph Mello, College of Engineering, Mechanical Engineering Department
Additional Advisors
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
Formula SAE is a collegiate competition hosted by SAE International with the primary goal being to design, manufacture, and race an open wheel race car. The Cal Poly Racing Formula SAE team strives for improvement every race season and has remained competitive as a result. The 2019-2020 management team determined that further research and development towards the chassis would yield the greatest performance benefit for future seasons, as the previous chassis platform limited packaging and mounting options for vehicle subsystems which interfaced with the chassis.
A redesign of the Cal Poly Racing Formula SAE team’s carbon fiber reinforced polymer monocoque chassis was requested to improve subsystem integration, increase torsional stiffness, and reduce weight compared to the previous platform. Specifically, this senior project team focused on manufacturing process improvement and laminate design to meet these goals for the 2020 Formula SAE competition.
This report details the design and manufacturing of such a chassis. Specific emphasis was placed on the geometry, laminate, and manufacturing process design. The geometry was designed using subsystem input for satisfactory integration of all subsystem components while maintaining a high specific torsional stiffness. The team also developed numerous analysis tools including spreadsheets and finite element models to design the asymmetric laminate of the chassis. Modular, multi-piece tooling was designed to produce a single-piece chassis and to allow for easy geometric changes in the future.
Though two complete chassis were delivered to the Formula SAE team, the outbreak of COVID-19 prevented the collection of data that would have been used to validate the design. However, the Formula SAE team was made aware of the validation plan proposed in this report.
URL: https://digitalcommons.calpoly.edu/mesp/561
Included in
Computer-Aided Engineering and Design Commons, Manufacturing Commons, Other Mechanical Engineering Commons, Structural Materials Commons