1. Für die Zukunft junger Ingenieure Chassis Design Space Frame 2009 Ronald Müller Gesamtfahrzeugleiter Rennteam Uni Stuttgart

2. Für die Zukunft junger Ingenieure Basics Rules and Rule Changes Concept Design Manufacturing Table of Contents

3. Für die Zukunft junger Ingenieure What is the frame? Connects all parts of the car Accommodates the driver What are the requirements? Needs to be lightweight and stiff Easy to manufacture Low in cost Basics

4. Für die Zukunft junger Ingenieure Why a space frame? Ideal for first year teams Load paths are easy to spot Manufacturing facilities are easy to find Material is cheap Basics

5. Für die Zukunft junger Ingenieure NOW YOU KNOW: The frame connects all parts of the car. It defines - together with the seat - the ergonomics of the driver It needs to be stiff and lightweight And the good news is: There is help! So you don't have to start from scratch: THE RULES! Rules & Rule Changes

6. Für die Zukunft junger Ingenieure The Rules define the most important tubes: Steel tubing for front and main roll hoops Main and front hoop bracing Side impact structure These make up the backbone of the front and middle of the frame. New this year: They also define the dimensions of the cockpit: THE TEMPLATES Rules & Rule Changes

7. Für die Zukunft junger Ingenieure Formula One Templates Rules & Rule Changes

8. Für die Zukunft junger Ingenieure 4.1 Cockpit Opening 4.1.1 In order to ensure that the opening giving access to the cockpit is of adequate size, a template shown in Figure 8 will be inserted into the cockpit opening. It will be held horizontally and inserted vertically until it has passed below the top bar of the Side Impact Structure (or until it is 350 mm above the ground for monocoque cars). 4.1.2 During this test, the steering wheel, steering column, seat and all padding may be removed. Rules & Rule Changes

9. Für die Zukunft junger Ingenieure Rules & Rule Changes 4.1 Cockpit Opening - Dimensions

10. Für die Zukunft junger Ingenieure 4.2 Cockpit Internal Cross Section: 4.2.1 A free vertical cross section, which allows the template shown in Figure 9 to be passed horizontally through the cockpit to a point 100 mm (4 inches) rearwards of the face of the rearmost pedal when in the inoperative position, must be maintained over its entire length. 4.2.2 The only things that may encroach on this area are the steering wheel, steering column and any padding that is required by Rule 5.7 Drivers Leg Protection. 4.2.3 For 2009, teams whose cars do not comply with 4.1 or 4.2 will have 35 points deducted from their Design Event score. Rules & Rule Changes

11. Für die Zukunft junger Ingenieure Rules & Rule Changes 4.1 Cockpit Internal Cross Section - Dimensions

12. Für die Zukunft junger Ingenieure NOW YOU KNOW: You know the basics and the rules to obey Many tube dimensions and positions are given The size of the drivers compartment is defined by the templates Now let's have a closer look at one possibility for designing your space frame. Rules & Rule Changes

13. Für die Zukunft junger Ingenieure Time Schedule Mockup Improve CAD-Model & Suspension Load Cases & Simple FEA CONCEPTDESIGNMANUFACTURING Improve CAD-Model & Suspension First CAD-Model Coordinating/Modification of CAD, Suspension & Mockup Improve CAD-Model & Suspension Detailed FEA Order Material! READ THE RULES! Tires & Suspension Assembly of the car cannot start until the frame is finished!

14. Für die Zukunft junger Ingenieure Ergonomic Research Get measurements of potential drivers in the team First draft of driver position, with engine and wheelbase (location of the tires) in place Concept

15. Für die Zukunft junger Ingenieure First CAD-Model CAD-Model considering rules and available space Make yourself placeholders to clarify the design envelope Concept

16. Für die Zukunft junger Ingenieure Mockup: Aim: define the major dimensions of the frame Build the first mockup as soon as possible Make yourself hardcopies of the templates and Percy Put the improvements back in CAD Interfaces with the suspension team Concept

17. Für die Zukunft junger Ingenieure Mockup: Concept

18. Für die Zukunft junger Ingenieure Load cases & Simple FEA Breaking, Acceleration, Cornering Beam/Truss Model Best way to optimize weight & stiffness Concept & Design

19. Für die Zukunft junger Ingenieure Use triangulations to avoid squares Design

20. Für die Zukunft junger Ingenieure Load initiation in nodes to prevent bending Design

21. Für die Zukunft junger Ingenieure Design ODIDWTICS 1210152734,558 12,710,90,9578,4632,987 Try to use big outer diameters and thin wall thickness (min. for welding 0.8mm) +10% bending stiffness -5% weight

22. Für die Zukunft junger Ingenieure Design ODIDWTICS 25202,511320,78176,72 25,420,62,411591,99173,42 3026217329,03175,93 Try to get as close to the minimum requirements as possible You cannot reduce weight as CS is prescribed Think about imperial tube sizes +53% bending stiffness e.g.: Mainhoop: Wall thickness 2mm

23. Für die Zukunft junger Ingenieure Try to lay the dampers parallel to tubes Design

24. Für die Zukunft junger Ingenieure Material Stiffness cannot be improved by using alloyed steel! Still it might be sensible to use alloyed steel for security relevant structures (cockpit, suspension) Heat treatment: It is definitively better to do it (Design) Do it locally to prevent huge distortion Welding TIG! Bending Use heat treated tubes for bending Design

25. Für die Zukunft junger Ingenieure Design St37 (1.0116) 25CrMo4 (1.7218) 15CDV6 (1.7765) Price++++- Welding++++++ Safetyo+++++ Choice++++ Material Wishbones, Suspension Front Vehicle, Cockpit

26. Für die Zukunft junger Ingenieure Order tubes early Laser cut the ends or grind with paper shape Manufacturing

27. Für die Zukunft junger Ingenieure Take your time to adjust the tubes properly before welding Manufacturing

28. Für die Zukunft junger Ingenieure 05. – 09. August 2009 See you in Hockenheim 2009