Design Optimization and Simulation Analysis of Formula SAE Frame Using Chromoly Steel

Abstract

Compliance with the rules and regulations of competition “Student Formula Car Racing” that conducted annually by the ‘Society of Automotive Engineers’ (SAE) India, the car frame must be designed and built with supreme priority. The major task posed is to design and fabricate a light weighed vehicle chassis frame without compensating the safety. This paper boards various methods of material selection, technical design optimization and Finite Element Analysis using ANSYS. The basic design is based on the anthropological study data of the specified human (95th percentile male) al-lowing fast ‘way-in’ and ‘way-out’ access from the car. According to the rules book specification on material selection, AISI 4130 chromoly steel was the first time identified for the frame design. Resulting in the final design of the vehicle frame, various analyses were done using ANSYS and the successive results are plotted and discussed. The entire design optimization and simulation analysis are based on the 2019 Formula SAE rules book. Keywords: finite element analysis, AISI 4130 chromoly steel, frame construction, Society of Automotive Engineers.