Chassis Simulations for 2021-03-21 Chassis Reinforcements

 

Considerations to Keep in Mind:

  1. Keep track of weight

    1. Standard weight that dynamics designs using is 720 kg.

    2. Calculate weight of tubes before adding the new tubes. Then calculate weight of tubes after new tubes are added. Calculate percentage difference. <5% difference is likely not a large concern

  2. Remember the complications in regards to welding.

    1. Should review and measure out chassis before finalizing tubes order

Chassis Before Any Modifications:

ASC Regulations Requirements:

Quick Overview of Vehicle Collision Loading Scenarios:

See Appendix F of ASC Regs 2021 for more details

 

First Reinforcement Attempt

12 new tubes

 

 

General Max Stresses:

4130 Chromoly - Yield Strength = 415 MPa

Loading Scenario

Approx. Absolute Max. Stress (MPa)

Loading Scenario

Approx. Absolute Max. Stress (MPa)

Front Bar

220

Back Bar

420

Side 30 Wall

1050

Side 60 Wall

750

A Pillar

1300

B Pillar

1800

C Pillar

1200

Front 30 Wall

1400

Front 60 Wall

900

Top 60 Wall

2500

Top

750

Top 30 Wall

1460

Combined Loading

Not Set-up Yet

Issue #1: Front Section - Collisions from the side - A Pillar Image

 

A lot of stress in the front half floor area. Will likely add more tubes on the lowest floor level shown in pink.

This would help resolve:

  • Side 30, Side 60, A Pillar

Issue #2: Mid Section - Collisions from the Side - B Pillar Image

A lot of stress on the B Pillar itself. Will likely add in B Bulkhead to reduce stress

This would help resolve:

  • B Pillar

A lot of stress on lower floor back half section. Will likely need horizontal tubes

This would help resolve:

  • C Pillar

 

Issue #3: Front Area - Front 30 Image

 

Issue #4: Top Long Round Tube Area - Top 60 Image

Second Reinforcement Attempt:

17 new tubes

B Bulkhead added

General Max Stresses

Loading Scenario

Approx. Absolute Max. Stress (MPa)

Loading Scenario

Approx. Absolute Max. Stress (MPa)

Front Bar

380

Back Bar

425

Side 30 Wall

1025

Side 60 Wall

990

A Pillar

1185

B Pillar

464

C Pillar

905

Front 30 Wall

1310

Front 60 Wall

770

Top 60 Wall

2620

Top

540

Top 30 Wall

1530

Combined Loading

Not Set-up Yet