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<!DOCTYPE html>
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<li class="toctree-l3"><a class="reference internal" href="#chassis-design-workflow">Chassis Design Workflow</a></li>
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<img alt="images/wallpaper.png" src="images/wallpaper.png" />
<div class="section" id="chassis-of-chimera-evoluzione">
<h1>Chassis of Chimera Evoluzione<a class="headerlink" href="#chassis-of-chimera-evoluzione" title="Permalink to this headline">¶</a></h1>
<img alt="images/design.png" src="images/design.png" />
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="section" id="engineering-specification">
<h2>Engineering Specification<a class="headerlink" href="#engineering-specification" title="Permalink to this headline">¶</a></h2>
<p>QFD diagram to understand parameters needed for an initial design, based on adversary teams.</p>
<img alt="images/designChassis1.png" src="images/designChassis1.png" />
</div>
<div class="section" id="chassis-design-workflow">
<h2>Chassis Design Workflow<a class="headerlink" href="#chassis-design-workflow" title="Permalink to this headline">¶</a></h2>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
</div>
<div class="section" id="configuration">
<h2>Configuration<a class="headerlink" href="#configuration" title="Permalink to this headline">¶</a></h2>
<p>3 different layout candidates were taken into FEM analysis to define a starting point. The one with better
torsional stiffness compared to the mass has been chosen as the basis for the following optimization
process.
Configuration 3 has been selected and taken into successive development.</p>
<div class="figure align-center" id="id1">
<img alt="images/designChassis2.png" src="images/designChassis2.png" />
<p class="caption"><span class="caption-text"><em>Configuration 1: Ks_torsion = 50.35 [Nm/° Kg]</em></span></p>
</div>
<div class="figure align-center" id="id2">
<img alt="images/designChassis3.png" src="images/designChassis3.png" />
<p class="caption"><span class="caption-text"><em>Configuration 2: Ks_torsion = 69.29 [Nm/° Kg]</em></span></p>
</div>
<div class="figure align-center" id="id3">
<img alt="images/designChassis4.png" src="images/designChassis4.png" />
<p class="caption"><span class="caption-text"><em>Configuration 3: Ks_torsion = 99.31 [Nm/° Kg]</em></span></p>
</div>
</div>
<div class="section" id="design-exploration">
<h2>Design Exploration<a class="headerlink" href="#design-exploration" title="Permalink to this headline">¶</a></h2>
<div class="section" id="input-parameters">
<h3>Input parameters:<a class="headerlink" href="#input-parameters" title="Permalink to this headline">¶</a></h3>
<blockquote>
<div><ul class="simple">
<li>Structure geometry variables:
- angles on side view
- lengths on side view
- widths on top view</li>
<li>Tubes cross section variables:
- Section Moment of Inertia
- Area cross Section</li>
</ul>
</div></blockquote>
<img alt="images/designChassis5.png" src="images/designChassis5.png" />
<img alt="images/designChassis6.png" src="images/designChassis6.png" />
</div>
<div class="section" id="output-parameters">
<h3>Output parameters:<a class="headerlink" href="#output-parameters" title="Permalink to this headline">¶</a></h3>
<blockquote>
<div><ul>
<li><p class="first">Torsional stiffness: main parameter for chassis design, crucial for vehicle performance.</p>
<img alt="images/designChassis/designChassis7a.png" src="images/designChassis/designChassis7a.png" />
</li>
<li><p class="first">Bending stiffness: chassis under load with a force directed downward in the driver cockpit area.</p>
<img alt="images/designChassis/designChassis7b.png" src="images/designChassis/designChassis7b.png" />
</li>
<li><p class="first">Braking stiffness: a rigid link simulates the contact point of the wheel on the ground. A force is applied on the center of gravity to simulate the braking phase.</p>
<img alt="images/designChassis/designChassis7c.png" src="images/designChassis/designChassis7c.png" />
</li>
</ul>
</div></blockquote>
</div>
</div>
<div class="section" id="parameters-correlation">
<h2>Parameters Correlation<a class="headerlink" href="#parameters-correlation" title="Permalink to this headline">¶</a></h2>
<dl class="docutils">
<dt><strong>Parameters correlation study allows to:</strong></dt>
<dd><ul class="first last simple">
<li>Determine which parameters have higher influence on the design</li>
<li>Find relationship grade between different parameters</li>
</ul>
</dd>
<dt><strong>Rank order clustering algorithms:</strong></dt>
<dd><ul class="first simple">
<li>Assign the binary weights with its help determination of the weight in decimal for each row and column</li>
<li>Rearrange the rows in the order of descending</li>
<li>Repeat steps 1 and 2 for every column. And the reiterate from step</li>
<li>The procedure has to be repeated till there reaches a point that the elements cannot be further changed from their positions.</li>
</ul>
<img alt="images/designChassis7.png" class="last" src="images/designChassis7.png" />
</dd>
</dl>
<p><strong>3 macro families found and taken into further development process:</strong></p>
<div class="figure align-center" id="id4">
<img alt="images/designChassis8.png" src="images/designChassis8.png" />
<p class="caption"><span class="caption-text"><strong>First Group:</strong></span></p>
<div class="legend">
<p>Variables: 7 (position)</p>
<p>Target: maximize Ks_bend and Ks_break</p>
<p>Main constraints: mass =< 30 Kg</p>
<p>Optimization method: MOGA (Multi-Objective Genetic Algorithm)</p>
</div>
</div>
<div class="figure align-center" id="id5">
<img alt="images/designChassis9.png" src="images/designChassis9.png" />
<p class="caption"><span class="caption-text"><strong>Second Group:</strong></span></p>
<div class="legend">
<p>Variables: 13 (lengths and angles)</p>
<p>Target: maximize Ks_torsion > 2000</p>
<p>Main constraints: mass =< 30 Kg</p>
<p>Optimization method: NLPQL (Nonlinear Programming by Quadratic Lagrangian)</p>
</div>
</div>
<div class="figure align-center" id="id6">
<img alt="images/designChassis10.png" src="images/designChassis10.png" />
<p class="caption"><span class="caption-text"><strong>Third Group:</strong></span></p>
<div class="legend">
<p>Variables: 17 (moment of inertia and tubes cross sectional area)</p>
<p>Target: maximize Ks_torsion > 2000</p>
<p>Main constraints: mass =< 30 Kg</p>
<p>Diameters and thickness from rules Optimization method: NLPQL (Nonlinear Programming by Quadratic Lagrangian)</p>
</div>
</div>
</div>
<div class="section" id="optimization-results">
<h2>Optimization Results<a class="headerlink" href="#optimization-results" title="Permalink to this headline">¶</a></h2>
<p>The black chassis represent the first design layout, before optimization.
The yellow chassis is the result after optimization</p>
<div class="figure">
<img alt="images/designChassis11.png" src="images/designChassis11.png" />
</div>
</div>
<div class="section" id="design-for-performance">
<h2>Design for Performance<a class="headerlink" href="#design-for-performance" title="Permalink to this headline">¶</a></h2>
<div class="section" id="fea-models">
<h3>FEA Models<a class="headerlink" href="#fea-models" title="Permalink to this headline">¶</a></h3>
<p><strong>Torsion</strong></p>
<div class="figure">
<img alt="images/designChassis12.png" src="images/designChassis12.png" />
</div>
<p><strong>Accelleration</strong></p>
<div class="figure">
<img alt="images/designChassis13.png" src="images/designChassis13.png" />
</div>
<p><strong>Bending</strong></p>
<div class="figure">
<img alt="images/designChassis14.png" src="images/designChassis14.png" />
</div>
</div>
<div class="section" id="final-design-results">
<h3>Final Design Results<a class="headerlink" href="#final-design-results" title="Permalink to this headline">¶</a></h3>
<div class="figure align-center">
<img alt="images/designChassis15.png" src="images/designChassis15.png" />
</div>
</div>
</div>
<div class="section" id="performance-evaluation">
<h2>Performance Evaluation<a class="headerlink" href="#performance-evaluation" title="Permalink to this headline">¶</a></h2>
<blockquote>
<div><ul class="simple">
<li>Torsion Analysis</li>
<li>Modal Analysis</li>
<li>Transient Analysis on circuit</li>
</ul>
</div></blockquote>
<div class="section" id="torsion-analysis">
<h3>Torsion analysis<a class="headerlink" href="#torsion-analysis" title="Permalink to this headline">¶</a></h3>
<p>k_torsion = 2054 Nm/° with rigid wishbones</p>
<div class="figure align-center">
<img alt="images/designChassis16.png" src="images/designChassis16.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis17.png" src="images/designChassis17.png" />
</div>
</div>
<div class="section" id="modal-analysis">
<h3>Modal analysis<a class="headerlink" href="#modal-analysis" title="Permalink to this headline">¶</a></h3>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="figure align-center">
<img alt="images/designChassis18.png" src="images/designChassis18.png" />
</div>
</div>
<div class="section" id="transient-analysis-on-circuit">
<h3>Transient Analysis on Circuit<a class="headerlink" href="#transient-analysis-on-circuit" title="Permalink to this headline">¶</a></h3>
<p>The trajectory plotted below is calculated to avoid the wheel slip with the highest possible speed. To find
the ideal path and the corresponding accelerations, a Matlab code has been developed. The data relating
to the accelerations and therefore the forces acting on the structure were transferred into the Ansys APDL
car model.</p>
<div class="figure align-center">
<img alt="images/designChassis19.png" src="images/designChassis19.png" />
</div>
<ul class="simple">
<li><strong>Colors:</strong><ul>
<li>Track Limits: Green</li>
<li>Tire Trajectory: Red</li>
<li>Car Centreline: Blue</li>
</ul>
</li>
</ul>
<div class="figure">
<img alt="images/designChassis20.png" src="images/designChassis20.png" />
</div>
<div class="figure">
<img alt="images/designChassis21.png" src="images/designChassis21.png" />
</div>
<div class="figure">
<img alt="images/designChassis22.png" src="images/designChassis22.png" />
</div>
<div class="figure">
<img alt="images/designChassis23.png" src="images/designChassis23.png" />
</div>
</div>
<div class="section" id="loads-on-tires">
<h3>Loads on Tires<a class="headerlink" href="#loads-on-tires" title="Permalink to this headline">¶</a></h3>
<p>To understand how the total structure is stressed the load history must be known. The starting point are the
reaction forces that the car receives from the ground through the wheels.
The plot below represents the tires reaction forces during the skid pad test. The weight car force was
considered in the dynamic load transfer.
Vertical loads results:</p>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<p>Grip limit values found during the tire analysis model:</p>
<blockquote>
<div><ul class="simple">
<li>1700 [N] for the front wheels</li>
<li>3800 [N] for the rear wheels.</li>
</ul>
</div></blockquote>
<p>Observing the lateral loads results can be seen that the rear wheels in the points of higher acceleration slip.
In fact, the springs that simulate the wheels give a reaction force higher than the real grip condition. This can
lead to have a peaks load on the structure higher to the actual ones.</p>
</div>
<div class="section" id="stress-analysis">
<h3>Stress analysis<a class="headerlink" href="#stress-analysis" title="Permalink to this headline">¶</a></h3>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<p>The stresses peaks occur during trajectory change. This happens when the machine moves from one circle to
the other during the skid pad test.</p>
</div>
<div class="section" id="chassis-torsion">
<h3>Chassis Torsion<a class="headerlink" href="#chassis-torsion" title="Permalink to this headline">¶</a></h3>
<p>To find the chassis torsion in Ansys, has been calculated the difference between the front and rear rotation
of the axes with respect to the roll center.</p>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<p>As can be seen from the chart above, the chassis behaves like a torsional spring due to the weight distribution
difference. The advantage of having such small deformations is that at each elastic return of the chassis in
the curve exit, there are less oscillations, resulting in a better drivability</p>
</div>
<div class="section" id="results-validation-model">
<h3>Results Validation Model<a class="headerlink" href="#results-validation-model" title="Permalink to this headline">¶</a></h3>
<p>Final results from the two software are plotted below:</p>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="figure align-center">
<img alt="images/designChassis25.png" src="images/designChassis25.png" />
</div>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
</div>
</div>
<div class="section" id="additive-manufacturing-integration">
<h2>Additive Manufacturing Integration<a class="headerlink" href="#additive-manufacturing-integration" title="Permalink to this headline">¶</a></h2>
<div class="section" id="the-idea-of-3d-printed-joints">
<h3>The idea of 3D printed joints<a class="headerlink" href="#the-idea-of-3d-printed-joints" title="Permalink to this headline">¶</a></h3>
<p>Once the X, Y, Z coordinates of the kinematic points have been defined, is mandatory to maintain the
maximum precision after the welding. Adding the brackets “by hand” using a complex support structure is
expensive, less precise and incline to misalignments and errors.</p>
<p>The possibility given by additive manufacturing allows to overcome many of those problems. The final
version of the joints has unique features:</p>
<blockquote>
<div><ul class="simple">
<li>Integrated suspension brackets</li>
<li>Topology optimized with internal ribs and variable thickness</li>
<li>Nesting guides for precise assembly, torque transmission, easier welding process</li>
<li>Allowing better electrical grounding across the entire structure</li>
<li>Head-to-head welding with tubes due to 4 spacers for each terminal</li>
</ul>
</div></blockquote>
<p>Design process illustration:</p>
<div class="figure align-center">
<img alt="images/designChassis26.png" src="images/designChassis26.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis27.png" src="images/designChassis27.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis29.png" src="images/designChassis29.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis29.png" src="images/designChassis29.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis30.png" src="images/designChassis30.png" />
</div>
</div>
<div class="section" id="fea-validation">
<h3>FEA Validation<a class="headerlink" href="#fea-validation" title="Permalink to this headline">¶</a></h3>
<div class="figure align-center">
<img alt="images/designChassis31.png" src="images/designChassis31.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis32.png" src="images/designChassis32.png" />
</div>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="figure align-center">
<img alt="images/designChassis34.png" src="images/designChassis34.png" />
</div>
</div>
</div>
<div class="section" id="nodes-reaction-forces-expressed-in-newtons">
<h2>NODES REACTION FORCES (EXPRESSED IN NEWTONS)<a class="headerlink" href="#nodes-reaction-forces-expressed-in-newtons" title="Permalink to this headline">¶</a></h2>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<div class="section" id="conclusion">
<h3>Conclusion<a class="headerlink" href="#conclusion" title="Permalink to this headline">¶</a></h3>
<p>In the first and the second plot the lines are essentially overlapped. This proves the validity of the Ansys
model. In the central zone of the curves, that corresponds to the work range, the lines are the basically the
same. The only difference can be seen in the final parts when the antiroll stiffness rear is low. This low value
generates a non-linearity in the Ansys model not expected in Matlab.
This non-linearity can be observed in the plot of the structure torsion in respect with the front antiroll
distribution stiffness:</p>
<div class="figure">
<img alt="images/designChassisgrafico" src="images/designChassisgrafico" />
</div>
<p>An assumption done in the Matlab analytical model is that the torsional stiffness of the structure is linear.
On the other hand, as can be seen from the above plot the structure behaviour coming from the Ansys model
it isn’t linear changing the front antiroll distribution stiffness. While calculating the stiffness of the structure
with shock absorbers infinitely rigid the stiffness response is linear.</p>
<div class="figure align-center">
<img alt="images/designChassis36.png" src="images/designChassis36.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis37.png" src="images/designChassis37.png" />
</div>
<p>Analysis before and after joints integration.
With the same loads and constraints applied, torsional stiffness has been increased by almost a factor of 3</p>
<div class="section" id="manufacturing-process">
<h4>Manufacturing Process<a class="headerlink" href="#manufacturing-process" title="Permalink to this headline">¶</a></h4>
<p>The addition of joints allows a much easier assembly and welding process, the structure can support itself
without requiring a complex tooling structure.
Weld bead is simpler and with more controlled thermal distribution.
Tubes laser cutting in easier, with less waste material.</p>
<div class="figure align-center">
<img alt="images/designChassis38.png" src="images/designChassis38.png" />
</div>
<div class="figure align-center">
<img alt="images/designChassis39.png" src="images/designChassis39.png" />
</div>
</div>
</div>
</div>
</div>
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