Fall 2020 - Chassis and Aerobody Project Discussion

Owned by Tommy Tran
Last updated: Nov 15, 2020
2 min read

Introduction

            The re-occurring theme of recent terms is that we have had to carry out re-designs on the Chassis because of the uncertainty surrounding the quality of our carbon fibre components that have been initially designated as being structural, i.e. the bottom panel, and A, B, and C bulkheads.

            The instinctive solution has been to accept that we would not be able to manufacture carbon fibre components that would meet their required standard and contribution for overall structural integrity of the car. We would then reinforce the Chassis in nearby areas to compensate for the lack of structural integrity.

            The latest findings from simulations have concluded that removing the bulkheads would, by a far margin, result in the Chassis not passing regulations. At this stage of the project, we have several options.


Table 1: Options and their pros and cons

Option

Pros

Cons

Manufacture new bulkheads that meet structural requirements

  • No re-design to the Chassis

  • Places pressure onto Aero to improve their layup quality

  • Increases timeline for Aero

Design the Chassis assuming there are no bulkheads;

Add the necessary tubes to pass regulations

  • Re-design to Chassis which calls for simulation work

  • Does not increase Aero timeline

  • Can be pushed to next term because tubes can be added as long as there’s no interference with existing assemblies

  • We can weld A-plane onto Chassis. We can trim Bulkhead A

  • Increases timeline for Chassis

Assess bulkhead properties and add minimum number of tubes

  • There might be less simulation work that needs to be done

  • Aero has to research non-destructive testing methods on manufactured bulkheads

  • Increases both aero and chassis timeline

 

Factors to be considered

  • Some points are impossible to achieve, e.g. it is close to impossible to improve layup quality in a short notice

  • People’s bandwidth as we enter the end of the term

  • Can certain options be pushed to the next term?

  • WE WOULDN’T BE ABLE TO ADD NEW TUBES AFTER CHASSIS HAS BEEN POWDER COATED