Chassis Task List

Get the metal structure to pass all collision scenarios and required structural regulations.

• Analyze all ANSYS simulations and get the failing sims to pass by adjusting tube size or adding gussets (or worst case adding more tubes).

Review on July 19, 2019

Get the chassis model to a point where it is fully trimmed and has been trimmed with DFM/DFA considered.

• Make sure tubes used are available from VR3.
• Make sure bends are within VR3's capabilities.
• Make sure the chassis is actually manufacturable and easy to assemble - think about which trim order would make it easiest for you to put it together.

Analyze the bottom panel with different loading scenarios and make sure it passes all of them.

• Once it passes the scenarios, start adding Unidirectional Tape to reinforce and try to reduce the # of 2 x 2 Twill Layers.
• Figure out which Nomex Core size to use - start with 5/8".
• Try reinforcing the weak points without adding too much weight. (e.g. instead of adding layers, selectively thicken certain parts or add Unidirectional to the load paths)
• Try to reduce weight while maintaining a high safety factor to account for manufacturing / other potential errors.

Figure out what stack ups to use for the rest of the panels.

• Goal is to reduce the weight of all of the non structural aerobody panels but still make them stiff enough to not flop around under their own weight.
• Could use cross bar or run core material in a cross shape to reinforce relatively flat panels.
• Run simulations of the part cantilevered at one end and add gravity to make sure it doesn't sag or flex a lot.

Complete the structure of the doors and add mounting points for hinges, latches, handles, and aerobody panels.

• Modify the CAD to make the doors fit inside the aerobody.
• Add mounting points and think about overall assembly of the door - how will all of the parts come together, what's the process and is it easy to take the door off/put it back on the car.
• Get the doors to pass regulations.

Outline a way to securely join the bottom panel to the metal structure, including the firewalls.

• Figure out which adhesive we want to use.
• How will we apply pressure on the bond line while it cures?
• Surface preparation.
• Accurately positioning the bottom panel to the metal structure.
  • Maybe a new fixture that aligns the bottom panel to the metal structure?
  • or use the welding fixture to help position the bottom panel?

Outline the tests we need to do, make test samples and do the tests.

• Figure out exactly how to do each test and which ones are required to fully characterize the material properties.
• Figure out how many samples and of what size we need for each of the tests.
• Once we get the material make the samples.

Design a fixture to precisely hold the chassis tubes in place so that they can be welded together.

• Use existing design of 8020 + tube clamps to make this.
• Will be a modification of the last welding jig - should be much simpler this time.
• If we can't hold all of the tubes at once then split it up into a few phases. 

Either buy or make our own flat sandwich panels.

• Check the price comparison for doing either of the methods and do the one that is more viable.
• Find water jetting place to accurately cut the panel to the shapes we want.

Design the seat structure to pass regulations and hold the weight of a person.

• Figure out how to attach seat to the bottom panel.
• Do hand calculations or simulations for loading on seat belt mounting points. (Might be easier to just do the hand calcs)
• DFM/DFA for seat structure (will be a bunch of flat panels that are cut to shape and put together like Lego).

Provide mounting points for dynamics and use the mounting points in the welding fixture.

• Suspension mounting.
• Steering mounting.
• Brakes mounting.

Figure out how to secure battery box to the bottom panel.