F1 CARS Chassis

F1 CARSF1 CARS

ChassisChassisChassis is a French term and was initially used to denote the Chassis is a French term and was initially used to denote the frame parts or Basic Structure of the vehicle. It is the back frame parts or Basic Structure of the vehicle. It is the back bone of the vehicle. A vehicle with out body is called Chassis. bone of the vehicle. A vehicle with out body is called Chassis. The components of the vehicle like Power plant, Transmission The components of the vehicle like Power plant, Transmission System, Axles, Wheels and Tyres, Suspension, Controlling System, Axles, Wheels and Tyres, Suspension, Controlling Systems like Braking, Steering etc., and also electrical system Systems like Braking, Steering etc., and also electrical system parts are mounted on the Chassis frame. It is the main parts are mounted on the Chassis frame. It is the main mounting for all the components including the body. So it is mounting for all the components including the body. So it is also called as Carrying Unit.also called as Carrying Unit.

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Design ConsiderationsDesign Considerations StiffnessStiffness Torsional stiffnessTorsional stiffness

Torsional stiffness is the resistance of the frame to torsional loadsTorsional stiffness is the resistance of the frame to torsional loads Bending StiffnessBending Stiffness

Bending stiffness is the resistance of the frame to bending loadsBending stiffness is the resistance of the frame to bending loads

WeightWeight

In body wherever possible, weight should be minimized. All tubing In body wherever possible, weight should be minimized. All tubing sizes were chosen to be as light as possible while remaining sizes were chosen to be as light as possible while remaining structurally sound and suitably stiff. Just as important as weight, structurally sound and suitably stiff. Just as important as weight, is mass moment of inertia. A car with a lower mass moment of is mass moment of inertia. A car with a lower mass moment of inertia will be able to turn more quickly. In order to reduce mass inertia will be able to turn more quickly. In order to reduce mass moment of inertia, all weight on the chassis is pushed as far as moment of inertia, all weight on the chassis is pushed as far as possible towards the centre of the vehicle. possible towards the centre of the vehicle.

Load pathLoad path

During the design process, it is important to consider how During the design process, it is important to consider how loads are passed into the frame. A load path describes the loads are passed into the frame. A load path describes the path through which forces are dissipated into the frame.path through which forces are dissipated into the frame.

Crash WorthinessCrash Worthiness

the car would be adequate for most possible crash situations. the car would be adequate for most possible crash situations. Due to the possibility of a head on collision, more structure Due to the possibility of a head on collision, more structure was placed in the nose of the framewas placed in the nose of the frame

ErgonomicsErgonomics

Properly incorporating the driver into a FSAE frame design can Properly incorporating the driver into a FSAE frame design can be very difficult because of wide variations in driver sizes. be very difficult because of wide variations in driver sizes. Each driver interface has to be designed so that it is Each driver interface has to be designed so that it is comfortable for a wide variety of drivers.comfortable for a wide variety of drivers.

Safety Harness Safety Harness

Most importantly, the attachment points of the harness must Most importantly, the attachment points of the harness must be strong enough to ensure that they will not fail during a be strong enough to ensure that they will not fail during a crash. They also must be positioned so that the buckles will crash. They also must be positioned so that the buckles will not bind when the harness is tightenednot bind when the harness is tightened

Controls Controls

Designing the frame around the controls, such as the steering Designing the frame around the controls, such as the steering wheel and pedals, is a matter of ensuring that the structure wheel and pedals, is a matter of ensuring that the structure of the frame does not interfere with the driver’s task. Also, of the frame does not interfere with the driver’s task. Also, the controls must be adequately supported by the frame so the controls must be adequately supported by the frame so that the attachment points do not yield while the car is that the attachment points do not yield while the car is being driven.being driven.

The CockpitThe Cockpit Cockpit is a space where interface of man and Cockpit is a space where interface of man and

machine occursmachine occurs Driver has limited movementDriver has limited movement Designers are forever trying to lower the centre of Designers are forever trying to lower the centre of

gravity of the car.gravity of the car.

Chassis Construction MethodsChassis Construction Methods Tubular space-frame Tubular space-frame

The most common frame type, the tubular space-frame, is a The most common frame type, the tubular space-frame, is a structure composed of many small, usually round tubes structure composed of many small, usually round tubes bent to shape and welded together. Tubular space-frames bent to shape and welded together. Tubular space-frames do not require specialized machinery or equipment for do not require specialized machinery or equipment for manufacture, and they are inexpensive and can be manufacture, and they are inexpensive and can be constructed from a wide variety of readily available constructed from a wide variety of readily available materials.materials.


Metal Monocoque Metal Monocoque

A monocoque chassis is a structure that constitutes both the A monocoque chassis is a structure that constitutes both the frame and the body. By combining these two critical frame and the body. By combining these two critical components into one piece, it is sometimes possible to components into one piece, it is sometimes possible to build a light car. In a metal monocoque design, the chassis build a light car. In a metal monocoque design, the chassis and body are fabricated from aluminium or steel sheet, and body are fabricated from aluminium or steel sheet, welded or riveted together.welded or riveted together.


Composite Monocoque Composite Monocoque

The strength to weight and stiffness to weight ratios of carbon The strength to weight and stiffness to weight ratios of carbon fibre and similar composite materials are generally much fibre and similar composite materials are generally much higher than those of steel or aluminium, However, composite higher than those of steel or aluminium, However, composite monocoque usually requires a unique mould for production, monocoque usually requires a unique mould for production, Composite monocoque is rarely easily repairable, and the Composite monocoque is rarely easily repairable, and the materials required for their construction are expensive and materials required for their construction are expensive and often difficult to work with.often difficult to work with.


Defining Structure of F1 frameDefining Structure of F1 frame

FrameFrameThe Frame is the fabricated structural assembly that supports all The Frame is the fabricated structural assembly that supports all functional vehicle systems. This assembly may be a single welded functional vehicle systems. This assembly may be a single welded structure, multiple welded structures or a combination of structure, multiple welded structures or a combination of composite and welded structures.composite and welded structures.The structure is comprised of following frame componentsThe structure is comprised of following frame componentsFront BulkheadFront BulkheadFront Roll HoopFront Roll HoopFront Hoop SupportFront Hoop SupportFront Bulkhead Support SystemFront Bulkhead Support SystemMain Hoop And Main Hoop BracingMain Hoop And Main Hoop BracingSide Impact MembersSide Impact MembersSide PodsSide PodsRear Bulkhead And Engine HousingRear Bulkhead And Engine Housing

Front BulkheadFront Bulkhead It is defined as“a planar structure that defines the forward It is defined as“a planar structure that defines the forward

plane of the Major Structure of the Frame and functions to plane of the Major Structure of the Frame and functions to provide protection for the driver’s feet”. The front bulkhead provide protection for the driver’s feet”. The front bulkhead is to be made from 1.0 inch diameter 0.063 inch wall is to be made from 1.0 inch diameter 0.063 inch wall thickness steel.thickness steel.

It is a rectangular It is a rectangular

structurestructure


Front Roll HoopFront Roll Hoop

The front roll hoop is “a roll bar located above the driver’s The front roll hoop is “a roll bar located above the driver’s legs, in proximity to the steering wheel.” The front roll hoop is legs, in proximity to the steering wheel.” The front roll hoop is to be made from 40mm diameter 0.079 inch wall thickness to be made from 40mm diameter 0.079 inch wall thickness steel. It must be tall steel. It must be tall

Enough to allow Enough to allow

drivers to fit into drivers to fit into

the chassis while the chassis while

passing the passing the

““2-inch rule,”2-inch rule,”


““2-inch rule,”2-inch rule,”

““2-inch rule” 2-inch rule”

states that a line drawn from the top of the main states that a line drawn from the top of the main hoop to the top of the front hoop must be at least 2 inches hoop to the top of the front hoop must be at least 2 inches from the top of any seated driver’s helmet. from the top of any seated driver’s helmet.


Front Hoop SupportFront Hoop Support This is the structure which connects the front hoop and front This is the structure which connects the front hoop and front

bulkhead. The rules state that the front bulkhead support bulkhead. The rules state that the front bulkhead support system must be made from 1.0 inch diameter 0.063 inch wall system must be made from 1.0 inch diameter 0.063 inch wall thickness steel tubing properly triangulated node-to-nodethickness steel tubing properly triangulated node-to-node

They must also be placedThey must also be placed

to accommodate feet of to accommodate feet of

the driver along with the the driver along with the

pedal assemblies and pedal assemblies and

steering rack.steering rack.

Front Bulkhead Support System Front Bulkhead Support System

The bulkhead support system was made by incorporating the The bulkhead support system was made by incorporating the front suspension box in a support structure that supports the front suspension box in a support structure that supports the front hoop support, bulkhead and triangulated with the base front hoop support, bulkhead and triangulated with the base rod.rod.


Main Hoop Main Hoop The main hoop is “a roll bar located alongside or just behind the The main hoop is “a roll bar located alongside or just behind the

driver’s torso.” The main hoop is to be constructed from 1.0 inch driver’s torso.” The main hoop is to be constructed from 1.0 inch diameter 0.079 inch wall thickness steel, the same material as diameter 0.079 inch wall thickness steel, the same material as the front hoop. It is constructed from a single piece, bent to the front hoop. It is constructed from a single piece, bent to shape.shape.

Main Hoop BracingMain Hoop Bracing The main hoop braces can be routed towards the front or The main hoop braces can be routed towards the front or

back of the chassis, but they must be securely integrated back of the chassis, but they must be securely integrated into the primary structure. In most cars, the braces are into the primary structure. In most cars, the braces are routed rearwards.routed rearwards.

Side Impact MembersSide Impact Members the driver must be protected by a side impact structure, the driver must be protected by a side impact structure,

composed of at least three tubes. There must be one upper composed of at least three tubes. There must be one upper side impact member, one lower side impact member, and side impact member, one lower side impact member, and one diagonal side impact member. The diagonal member one diagonal side impact member. The diagonal member can be more than one tube if it is properly triangulatedcan be more than one tube if it is properly triangulated

Minimum wall thickness should be 0.047 inchMinimum wall thickness should be 0.047 inch

Side PodsSide Pods Side pod members are used to increase Area Momont of Side pod members are used to increase Area Momont of

Inertia thus increasing Stiffness of BodyInertia thus increasing Stiffness of Body Side pod structure also constitute as side impact structure.Side pod structure also constitute as side impact structure. A triangular planar structure is taken to make the design A triangular planar structure is taken to make the design

simple and rigid.simple and rigid.

Rear Bulkhead And The Engine Rear Bulkhead And The Engine HousingHousing

The rear of the chassis is composed of the rear bulkhead The rear of the chassis is composed of the rear bulkhead and the engine housing. The housing is designed according and the engine housing. The housing is designed according to the engine size and possibility of a very rigid and stable to the engine size and possibility of a very rigid and stable engine mountengine mount

The engine housing members are designed so, that it The engine housing members are designed so, that it should take all the engine load both static and dynamic.should take all the engine load both static and dynamic.

MaterialsMaterials Material is selected on the basis of its light weight and easily Material is selected on the basis of its light weight and easily

accessibilityaccessibility The materials like steel, aluminium, Glass fiber, carbon fiber which The materials like steel, aluminium, Glass fiber, carbon fiber which

are commonly used in F1 chassisare commonly used in F1 chassis

SteelSteel

The most common material for tubular space-frames, steel retains its The most common material for tubular space-frames, steel retains its strength and ductility after welding. It is inexpensive, easy to find, strength and ductility after welding. It is inexpensive, easy to find, and easy to cut and grind. The Supra SAE rules dictate tubing sizes and easy to cut and grind. The Supra SAE rules dictate tubing sizes for steel, and the use of any other material requires the completion for steel, and the use of any other material requires the completion of a structural equivalency formof a structural equivalency form

AluminiumAluminium Generally, aluminium is used because of its low density (2.69g/cc) . Generally, aluminium is used because of its low density (2.69g/cc) .

When considering aluminium, like any material, we must consider When considering aluminium, like any material, we must consider the advantages, disadvantages, and possible production processes. the advantages, disadvantages, and possible production processes.

Aluminium is a favourable material such that it has a low density, Aluminium is a favourable material such that it has a low density,

it is corrosion resistant, it is easily obtained and can be recycled; it is corrosion resistant, it is easily obtained and can be recycled; however aluminium also has a high and fluctuating cost, is less however aluminium also has a high and fluctuating cost, is less formable than steel and less readily welded. There are many formable than steel and less readily welded. There are many aluminium alloys available which can be selected to suit the aluminium alloys available which can be selected to suit the formability and strength requirements.formability and strength requirements.

Glass Fibre Glass Fibre Commonly known as fibreglass, GFRP is widely used in the Commonly known as fibreglass, GFRP is widely used in the

automotive industry. GFRP is favourable due to its high automotive industry. GFRP is favourable due to its high formability, controllability of material properties, wide scope of formability, controllability of material properties, wide scope of applications, and relative ease of production, especially in small applications, and relative ease of production, especially in small scale operations.scale operations.

GFRP has a lower density than that of aluminium however its GFRP has a lower density than that of aluminium however its production must be carefully controlled to achieve the desired production must be carefully controlled to achieve the desired material properties. It is easily formable but not easily repairable material properties. It is easily formable but not easily repairable and cannot be recycled. GFRP offers good corrosion resistance as and cannot be recycled. GFRP offers good corrosion resistance as well as good dimensional stability and scratch resistance well as good dimensional stability and scratch resistance qualities.qualities.

Carbon FibreCarbon Fibre Commonly known as carbon fibre, Carbon fibre is very Commonly known as carbon fibre, Carbon fibre is very

similar in its advantages and disadvantages to Glass fibre similar in its advantages and disadvantages to Glass fibre however it has a lower density and higher strength. These however it has a lower density and higher strength. These improved material properties invariably lead to a high improved material properties invariably lead to a high material cost however weight savings of up to 30% make material cost however weight savings of up to 30% make this cost an acceptable one.this cost an acceptable one.

Carbon Fibre vs. Other Materials Carbon Fibre vs. Other Materials The main attraction of carbon fibre for Formula 1 chassis’s The main attraction of carbon fibre for Formula 1 chassis’s

is the amazing strength and stiffness for its weight. No other is the amazing strength and stiffness for its weight. No other material comes close to carbon fibre in terms of specific material comes close to carbon fibre in terms of specific weight and stiffness. weight and stiffness.

Stiffness Stiffness Next figure shows the specific stiffness (the rigidity of the Next figure shows the specific stiffness (the rigidity of the

material for every unit of it’s weight) as a function of the material for every unit of it’s weight) as a function of the specific stiffness of high stiffness carbon fibre. specific stiffness of high stiffness carbon fibre.

As can be clearly seen, carbon fibre has a specific stiffness As can be clearly seen, carbon fibre has a specific stiffness in the order of 2-3 times that of conventional metals such in the order of 2-3 times that of conventional metals such as steel and aluminium.as steel and aluminium.


StrengthStrength

The same analysis with strength shows that carbon fibre has a specific strength over ten times that of basic steel.

Combining the increased strength and stiffness properties of carbon fibre compared to conventional metals and alloys, it is by far the best material for the construction of Formula 1 chassis

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F1 CARS Chassis

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