Structural Durability Study for Formula SAE Chassis System through Finite Element Method

This study aims to develop a virtual structural durability procedure for the formula SAE chassis and apply it on 2015 Maua Racing vehicle in order to identify potential durability concern areas and mass reduction areas. Quasi-static load cases were developed, based upon acceleration experimental data and analytical load transfer function, to represent the vehicle dynamic behavior at several work conditions. Virtual simulations (multibody and finite elements) indicate that 2015 chassis meets the targeted durability criteria for both peak loading and fatigue damage. Borderline regions were verified considering peak loading target and a special attention should be paid to them during reduction mass studies avoiding the target violation. Other regions present structural stress considerably lower than material capability, what indicates significant mass reduction potential. Overall, this study is understood to contribute for both academic and industrial areas as it provides a structural performance prediction process at component, subsystem and vehicle level that enables performance improvement and cost reduction by means of using information that is normally available in the beginning of the development.