This year’s space frame design was fabricated in house. The team utilized 1 inch outer diameter circular tubing made from 4130 Chromoly steel with varying wall thicknesses of 0.095, 0.065, and 0.049 inches. Also, to reduce weight, the team used 5/8 inch outer diameter circular tubing with a wall thickness of 0.035 inches wherever possible. The team began to design the frame using SolidWorks and performed analysis in Pro/Engineer Mechanica. This consisted of finite element analysis (FEA) on the structure, with forces applied through the suspension mounting points. Torsional rigidity analysis was also performed using Mechanica. This analysis was validated by testing the completed frame. The suspension mounting tabs were also analyzed using Mechanica. The final weight of the frame, including tabs, is 68 lbs. The design weight of the vehicle is 500 lbs. The design of the frame results in a vehicle with an overall width of 62 in, height of 43.5 in, and length of 95 in (not including the length of the impact attenuator and nosecone).

 

The team has chosen to construct a honeycomb foil impact attenuator from 3003 Aluminum alloy. The material has a rated energy absorption capacity of 9,819 Joules with its specific dimensions. This rated characteristic was validated through a quasi-static crush test to ensure the validity of the energy capacity. The impact attenuator has a crush zone length of 8 inches, a width of 8 inches and a height of 4 inches.

 

The Frame and Ergonomics team is also responsible for designing the gas tank for the vehicle. The gas tank has a fuel capacity of 1.9 gallons. It is made from aluminum sheeting with internal baffles to reduce the motion of the fuel during the events. The tank is mounted on the floor between the firewall and engine. Finally, the Frame and Ergonomics Team is responsible for seating (ergonomics), the dashboard, and placement of the firewall, floor, and body panels.

3/1/2012
Team 17 is the 2012 FSAE frame team and is in charge of designing and manufacturing a frame that will utilize space frame techniques and technology. In addition to manufacturing the frame, Team 17 will undertake the task of making a driver seat, a gas tank, and an impact attenuator. The design of the frame must meet the requirements set forth by the 2012 FSAE rules and regulations which pertain to safety, rough dimensions of the car and driver call, and specifications of materials to be used. Furthermore, the team has set its own standards in terms of an overall weight, a low center of gravity, and set torsional and bending rigidity.

Our aims are to have an overall wheelbase of 62-inches, a frame weight of approximately 66-lbs, and an aimed torsional rigidity of 1150 lbf/degree. Moreover, the team sets to have a frame with a smart design that will have a high level of simplicity when it comes to manufacturing, while maintaining safety and competitiveness on race day.

This year the Team is composed of:
Simon Doornbos (Team Captain)
Jon Gray
Dan Simms
Kyle Wineinger