Selection of Materials, Design and Analysis of FSAE Chassis for Different Engineering Application- A Comprehensive Review

Year 2025, Volume: 9 Issue: 1, 136 - 157, 31.03.2025

Mantesh Khot , Chinmya K A , Mahesh S , Suprith S , Manish M

https://doi.org/10.30939/ijastech..1574611

Abstract

The paper addresses some important developments in tubular space frame chassis design which have been pivotal in many engineering and automobile applications. Light weight and high stiffness-to-weight ratio tubular space frame chassis have been widely studied for their performance in motorsports and high-performance vehicles. However, their tendency to fail under extreme stresses emphasizes the importance of rigorous design optimization. This study focuses on the significance of topology optimization a process that refines material distribution within a given design space to enhance structural efficiency. This approach not only improves performance but also reduces material consumption, which leads to cost savings and environmental sustainability. Material selection is the critical aspect of chassis design, where Al-SiC composites are preferred for their strength, wear resistance, and lightweight properties. The integration of methodologies such as force modeling equations, computer aided design (CAD), and finite element analysis (FEA) is emphasized as a core part of the design process. Tools like SolidWorks and ANSYS are highlighted, particularly in the areas of chassis modeling with high precision and structural analysis that ensures designs meet the high standards set by Formula Society of Automotive Engineers (FSAE). Simulation based optimization by ANSYS Mechanical will, therefore play an important role in ascertaining the validation of the structural integrity and the performance of the chassis at a real-world environment by simulating stresses, strains, and displacements so that there could be a probable prediction of failure and, consequently, design refinement. By using this methodology, safety, performance, and cost effectiveness in designing FSAE chassis would comply with FSAE regulations. The integration of cutting-edge technologies and materials ensures that chassis designs meet the evolving demands of modern applications. This comprehensive review serves as a valuable guide for researchers and engineers, emphasizing the interplay of design optimization, material science, and computational tools in achieving efficient and sustainable chassis designs.

Keywords

Aluminum Silicon Carbide [Al-SiC], Finite Element Analysis [FEA], Formula Society of Automotive Engineers [FSAE], Multi-Directional Impact Analysis, Tubular Space Frame Chassis

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