The proposed Gen2 rear subframe is an all-new concept designed to be a complete rear-end subassembly, which replaces the conventional rear frame of a car. A reliable, lightweight, simple, and cost-effective design has been developed to improve the James Cook University (JCU)’s Formula Society of Automotive Engineers (FSAE) car performance in competition.
Through the use of numerical simulation, theoretical computations, and research, refinement of the concept was conducted until a compromise between reliability and lightweight design was found. Taking into consideration accurate loadings acting on the assembly, critical areas of stress were found in the solid drive axle with a maximum Von Mises stress of 151 MPa and overall Factor of Safety (FOS) of 2.11 located on the drive splines of the shaft.
All simulations are verified with the use of theoretical calculations, making the results reliable and accurate. Off-the-shelf items are verified to withstand all loads, and the designs meet the relevant guidelines (Australian Standard [AS] or other) and FSAE requirements. Simplicity has been kept in mind throughout the entire project to help reduce manufacturing costs yet make a reliable model.