The Objective
Design a rigid, lightweight frame accommodating drivetrain, steering, and braking systems while meeting strict safety margins under competition regulations. The challenge lay in engineering sufficient torsional compliance to aid mechanical cornering grip without sacrificing structural integrity under high-g lateral transitions.
Engineering & Analysis (SOLIDWORKS FEA)
Conducted structural FEA in SOLIDWORKS to maximize torsional rigidity under quasi-static cornering loads while minimizing total chassis weight. Evaluated von Mises stress distributions across static baseline loading, left cornering quasi-static load cases, and right cornering quasi-static load cases to ensure stress concentrations remained well below yield across all welded junctions.
Kinematics & Stability
Strategically lengthened the wheelbase to improve high-speed directional stability and reduce snap-oversteer. Positioned mounting plates and seat placement to optimize the longitudinal and lateral center of gravity (CG), resulting in predictable weight transfer during heavy braking into hairpins.
Fabrication & Fixturing Strategy
Constructed a full-scale CNC-routed plywood jig to locate and hold raw A513 square tubing segments rigid during tacking and final weld passes. This fixturing technique completely eliminated thermal distortion across diagonal frame rails, guaranteeing true parallel steering knuckle geometry and drivetrain alignment. A plasma-cut steel floorpan was fused to act as a structural shear plate, significantly enhancing plane torsional stiffness.
Competition Results
Achieved a competitive chassis that posted lap times 6 seconds faster than competitors across a 24-second course circuit. The frame passed all pre-race technical inspections on first pass and maintained structural alignment throughout multiple heat cycles.
