Design, analysis and experimental verification of tubular spaceframe chassis for FSAE application

Appendices 5 - Data Acquisition on the Operation load of Chassis – X1-6A Accelerometer 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 Appendices 6- Data Acquisition on the Operation load of Chassis – Acquired Data 1) Skid pad Event Graph 70- Lateral, associated longitudinal and vertical acceleration experienced by the front left unsprung mass of the race car during skid pad event 288 Graph 71-Lateral, associated longitudinal and vertical acceleration experienced by the front right unsprung mass of the race car during skid pad event 289 Graph 72-Lateral, associated longitudinal and vertical acceleration experienced by the rear left unsprung mass of the race car during skid pad event 290 Graph 73-Lateral, associated longitudinal and vertical acceleration experienced by the rear right unsprung mass of the race car during skid pad event 291 Graph 74-Lateral, associated longitudinal and vertical acceleration experienced by the race car at the center of gravity (CG) during skid pad event 292 2) Acceleration and Brake Test Graph 75-Longitudinal, associated lateral and vertical acceleration experienced by the front left unsprung mass of the race car during acceleration and brake test 293 Graph 76-Longitudinal, associated lateral and vertical acceleration experienced by the front right unsprung mass of the race car during acceleration and brake test 294 Graph 77-Longitudinal, associated lateral and vertical acceleration experienced by the rear left unsprung mass of the race car during acceleration and brake test 295 Graph 78-Longitudinal, associated lateral and vertical acceleration experienced by the rear right unsprung mass of the race car during acceleration and brake test 296 Graph 79-Longitudinal, associated lateral and vertical acceleration experienced by the race car at the center of gravity (CG) during acceleration and brake test 297 Appendices 7 - Research on Stressed Skin Construction for Chassis 1) Torsional Test on Bare Frame Structural Torsional Stiffness of Bare Frame (TT1) 100.00 90.00 y = 305.79x - 0.05 (Loading) 80.00 y = 308.12x - 1.04 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 0.200 Angular Deflection (deg) Loading 0.250 0.300 0.350 Unloading Graph 80-Structural torsional stiffness bare frame (round 1) 298 Structural Torsional Stiffness of Bare Frame (TT2) 100.00 90.00 y = 306.37x + 0.11 (Loading) 80.00 y = 307.37x - 0.57 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 0.200 Angular Deflection (deg) Loading 0.250 0.300 0.350 Unloading Graph 81-Structural torsional stiffness bare frame (round 2) 299 Structural Torsional Stiffness of Bare Frame (TT3) 100.00 90.00 y = 304.84x + 1.09 (Loading) 80.00 y = 307.83x - 0.29 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 0.200 Angular Deflection (deg) Loading 0.250 0.300 0.350 Unloading Graph 82-Structural torsional stiffness bare frame (round 3) 300 Structural Torsional Stiffness of Bare Frame (TT4) 100.00 90.00 y = 304.34x - 0.08 (Loading) 80.00 y = 306.45x - 1.15 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 Angular Deflection (deg) Loading 0.200 0.250 0.300 Unloading Graph 83-Structural torsional stiffness bare frame (round 4) 301 Structural Torsional Stiffness of Bare Frame (TT5) 100.00 90.00 y = 305.08x - 0.21 (Loading) 80.00 y = 306.85x - 1.00 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 Angular Deflection (deg) Loading 0.200 0.250 0.300 Unloading Graph 84-Structural torsional stiffness bare frame (round 5) 302 Structural Torsional Stiffness of Bare Frame (TT6) 100.00 90.00 y = 305.46x - 0.22 (Loading) 80.00 y = 307.11x - 1.01 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 Angular Deflection (deg) Loading 0.200 0.250 0.300 Unloading Graph 85-Structural torsional stiffness bare frame (round 6) 303 2) Torsional Test on “Spaceframe” Frame Structural Torsional Stiffness of Spaceframe Frame (TT1) 100.00 90.00 y = 630.49x + 0.58 (Loading) 80.00 y = 634.74x - 0.74 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 86-Structural torsional stiffness “Spaceframe” frame (round 1) 304 Structural Torsional Stiffness of Spaceframe Frame (TT2) 100.00 90.00 y = 631.52x + 0.55 (Loading) 80.00 y = 637.05x - 1.11 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 87-Structural torsional stiffness “Spaceframe” frame (round 2) 305 Structural Torsional Stiffness of Spaceframe Frame (TT3) 100.00 90.00 y = 633.11x + 0.74 (Loading) 80.00 y = 636.45x - 0.46 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 Loading 0.060 Unloading 0.080 Angular Deflection (deg) Linear (Loading) 0.100 0.120 0.140 0.160 Linear (Unloading) Graph 88-Structural torsional stiffness “Spaceframe” frame (round 3) 306 Structural Torsional Stiffness of Spaceframe Frame (TT4) 100.00 90.00 y = 580.93x + 0.36 (Loading) 80.00 y = 585.17x - 1.08 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 89-Structural torsional stiffness “Spaceframe” frame (round 4) 307 Structural Torsional Stiffness of Spaceframe Frame (TT5) 100.00 90.00 y = 581.40x + 1.01 (Loading) 80.00 y = 584.31x - 0.75 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 90-Structural torsional stiffness “Spaceframe” frame (round 5) 308 Structural Torsional Stiffness of Spaceframe Frame (TT6) 100.00 90.00 y = 576.76x + 0.60 (Loading) 80.00 y = 582.96x - 1.03 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 91-Structural torsional stiffness “Spaceframe” frame (round 6) 309 3) Torsional Test on “Stressed Skin” Frame Structural Torsional Stiffness of Stress Skin Frame (TT1) 100.00 90.00 y = 1066.17x + 1.96 (Loading) 80.00 y = 1120.97x - 3.69 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 0.030 0.040 0.050 Angular Deflection (deg) Loading 0.060 0.070 0.080 0.090 Unloading Graph 92-Structural torsional stiffness “Stressed Skin” frame (round 1) 310 Structural Torsional Stiffness of Stress Skin Frame (TT2) 100.00 90.00 y = 1113.02x + 1.92 (Loading) 80.00 y = 1125.04x - 1.23 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 0.030 0.040 0.050 Angular Deflection (deg) Loading 0.060 0.070 0.080 0.090 Unloading Graph 93-Structural torsional stiffness “Stressed Skin” frame (round 2) 311 Structural Torsional Stiffness of Stress Skin Frame (TT3) 100.00 90.00 y = 1106.50x + 2.56 (Loading) 80.00 y = 1118.96x - 0.68 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 Loading 0.030 Unloading 0.040 0.050 Angular Deflection (deg) Linear (Loading) 0.060 0.070 0.080 0.090 Linear (Unloading) Graph 94-Structural torsional stiffness “Stressed Skin” frame (round 3) 312 Structural Torsional Stiffness of Stress Skin Frame (TT4) 100.00 90.00 y = 990.29x + 0.30 (Loading) 80.00 y = 999.53x - 1.06 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 0.030 0.040 0.050 0.060 Angular Deflection (deg) Loading 0.070 0.080 0.090 0.100 Unloading Graph 95-Structural torsional stiffness “Stressed Skin” frame (round 4) 313 Structural Torsional Stiffness of Stress Skin Frame (TT5) 100.00 90.00 y = 989.91x + 0.05 (Loading) 80.00 y = 1001.08x - 1.44 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 0.030 0.040 0.050 0.060 Angular Deflection (deg) Loading 0.070 0.080 0.090 0.100 Unloading Graph 96-Structural torsional stiffness “Stressed Skin” frame (round 5) 314 Structural Torsional Stiffness of Stress Skin Frame (TT6) 100.00 90.00 y = 998.00x + 0.31 (Loading) 80.00 y = 1000.06x - 0.45 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.010 0.020 0.030 0.040 0.050 0.060 Angular Deflection (deg) Loading 0.070 0.080 0.090 0.100 Unloading Graph 97-Structural torsional stiffness “Stressed Skin” frame (round 6) 315 4) Simply Supported Bending Test on Bare Frame Structural Bending Stiffness of Bare Frame (SSBT 1) 350.00 300.00 y = 1765114.22x + 0.95 (Loading) 250.00 Weight (N) y = 1779903.26x - 2.10 (Unloading) 200.00 150.00 100.00 50.00 0.00 0.00000 0.00002 0.00004 0.00006 0.00008 0.00010 Downwards Displacement (m) Loading 0.00012 0.00014 0.00016 0.00018 Unloading Graph 98-Structural bending stiffness of bare frame (round 1) 316 Structural Bending Stiffness of Bare Frame (SSBT 2) 350.00 300.00 y = 1762271.46x + 0.61 (Loading) 250.00 Weight (N) y = 1774169.09x - 2.32 (Unloading) 200.00 150.00 100.00 50.00 0.00 0.00000 0.00002 0.00004 0.00006 0.00008 0.00010 Downwards Displacement (m) Loading 0.00012 0.00014 0.00016 0.00018 Unloading Graph 99-Structural bending stiffness of bare frame (round 2) 317 Structural Bending Stiffness of Bare Frame (SSBT 3) 350.00 300.00 y = 1766498.59x - 0.36 (Loading) 250.00 y = 1775057.92x - 2.52 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.00000 -50.00 0.00002 0.00004 0.00006 0.00008 0.00010 0.00012 0.00014 0.00016 0.00018 Downwards Displacement (m) Loading Unloading Graph 100-Structural bending stiffness of bare frame (round 3) 318 5) Simply Supported Bending Test on “Spaceframe” Frame Structural Bending Stiffness of Spaceframe Frame (SSBT 1) 350.00 300.00 y = 3350347.49x - 1.36 (Loading) 250.00 y = 3386689.80x - 4.88 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.00000 -50.00 0.00001 0.00002 0.00003 0.00004 0.00005 0.00006 0.00007 0.00008 0.00009 Downwards Displacement (m) Loading Unloading Graph 101-Structural bending stiffness of “Spaceframe” frame (round 1) 319 Structural Bending Stiffness of Spaceframe Frame (SSBT 2) 350.00 300.00 y = 3369625.17x + 0.08 (Loading) 250.00 y = 3341196.44x - 0.01 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.00000 -50.00 0.00001 0.00002 0.00003 0.00004 0.00005 0.00006 0.00007 0.00008 0.00009 Downwards Displacement (m) Loading Unloading Graph 102-Structural bending stiffness of “Spaceframe” frame (round 2) 320 Structural Bending Stiffness of Spaceframe Frame (SSBT 3) 350.00 300.00 y = 3366104.36x - 0.97 (Loading) 250.00 y = 3354282.16x - 0.46 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.00000 -50.00 0.00001 0.00002 0.00003 0.00004 0.00005 0.00006 0.00007 0.00008 0.00009 0.00010 Downwards Displacement (m) Loading Unloading Graph 103-Structural bending stiffness of “Spaceframe” frame (round 3) 321 6) Simply Supported Bending Test on “Stressed Skin” Frame Structural Bending Stiffness of Stress Skin Frame (SSBT 1) 350.00 300.00 y = 14187506.35x - 18.54 (Loading) 250.00 y = 14684688.81x - 49.43 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.000000 -50.00 0.000005 0.000010 0.000015 0.000020 0.000025 Downwards Displacement (m) Loading Unloading Graph 104-Structural bending stiffness of “Stressed Skin” frame (round 1) 322 Structural Bending Stiffness of Stress Skin Frame (SSBT 2) 350.00 300.00 y = 12623625.94x - 40.23 (Loading) 250.00 y = 14194801.45x - 89.60 Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.000000 0.000005 0.000010 0.000015 0.000020 0.000025 0.000030 -50.00 -100.00 Downwards Displacement (m) Loading Unloading Graph 105-Structural bending stiffness of “Stressed Skin” frame (round 2) 323 Structural Bending Stiffness of Stress Skin Frame (SSBT 3) 350.00 300.00 y = 12207954.26x - 38.07 (Loading) 250.00 y = 13686807.11x - 94.41 (Unloading) Weight (N) 200.00 150.00 100.00 50.00 0.00 0.000000 0.000005 0.000010 0.000015 0.000020 0.000025 0.000030 -50.00 -100.00 Downwards Displacement (m) Loading Unloading Graph 106-Structural bending stiffness of “Stressed Skin” frame (round 3) 324 [...]... left unsprung mass of the race car during acceleration and brake test 295 Graph 78-Longitudinal, associated lateral and vertical acceleration experienced by the rear right unsprung mass of the race car during acceleration and brake test 296 Graph 79-Longitudinal, associated lateral and vertical acceleration experienced by the race car at the center of gravity (CG) during acceleration and brake test 297... 75-Longitudinal, associated lateral and vertical acceleration experienced by the front left unsprung mass of the race car during acceleration and brake test 293 Graph 76-Longitudinal, associated lateral and vertical acceleration experienced by the front right unsprung mass of the race car during acceleration and brake test 294 Graph 77-Longitudinal, associated lateral and vertical acceleration experienced... load of Chassis – Acquired Data 1) Skid pad Event Graph 70- Lateral, associated longitudinal and vertical acceleration experienced by the front left unsprung mass of the race car during skid pad event 288 Graph 71-Lateral, associated longitudinal and vertical acceleration experienced by the front right unsprung mass of the race car during skid pad event 289 Graph 72-Lateral, associated longitudinal and. .. left unsprung mass of the race car during skid pad event 290 Graph 73-Lateral, associated longitudinal and vertical acceleration experienced by the rear right unsprung mass of the race car during skid pad event 291 Graph 74-Lateral, associated longitudinal and vertical acceleration experienced by the race car at the center of gravity (CG) during skid pad event 292 2) Acceleration and Brake Test Graph... Torsional Stiffness of Spaceframe Frame (TT4) 100.00 90.00 y = 580.93x + 0.36 (Loading) 80.00 y = 585.17x - 1.08 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 89-Structural torsional stiffness Spaceframe frame (round 4) 307 Structural Torsional Stiffness of Spaceframe Frame... torsional stiffness Spaceframe frame (round 1) 304 Structural Torsional Stiffness of Spaceframe Frame (TT2) 100.00 90.00 y = 631.52x + 0.55 (Loading) 80.00 y = 637.05x - 1.11 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 0.060 0.080 Angular Deflection (deg) Loading 0.100 0.120 0.140 0.160 Unloading Graph 87-Structural torsional stiffness Spaceframe frame... Stiffness of Bare Frame (TT6) 100.00 90.00 y = 305.46x - 0.22 (Loading) 80.00 y = 307.11x - 1.01 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 Angular Deflection (deg) Loading 0.200 0.250 0.300 Unloading Graph 85-Structural torsional stiffness bare frame (round 6) 303 2) Torsional Test on Spaceframe Frame Structural Torsional Stiffness of Spaceframe. .. Structural Torsional Stiffness of Spaceframe Frame (TT3) 100.00 90.00 y = 633.11x + 0.74 (Loading) 80.00 y = 636.45x - 0.46 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.020 0.040 Loading 0.060 Unloading 0.080 Angular Deflection (deg) Linear (Loading) 0.100 0.120 0.140 0.160 Linear (Unloading) Graph 88-Structural torsional stiffness Spaceframe frame (round 3) 306... acceleration experienced by the race car at the center of gravity (CG) during acceleration and brake test 297 Appendices 7 - Research on Stressed Skin Construction for Chassis 1) Torsional Test on Bare Frame Structural Torsional Stiffness of Bare Frame (TT1) 100.00 90.00 y = 305.79x - 0.05 (Loading) 80.00 y = 308.12x - 1.04 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000... Structural Torsional Stiffness of Bare Frame (TT2) 100.00 90.00 y = 306.37x + 0.11 (Loading) 80.00 y = 307.37x - 0.57 (Unloading) Torque (Nm) 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 0.000 0.050 0.100 0.150 0.200 Angular Deflection (deg) Loading 0.250 0.300 0.350 Unloading Graph 81-Structural torsional stiffness bare frame (round 2) 299 Structural Torsional Stiffness of Bare Frame (TT3) 100.00 90.00 ... center of gravity (CG) during acceleration and brake test 297 Appendices - Research on Stressed Skin Construction for Chassis 1) Torsional Test on Bare Frame Structural Torsional Stiffness of Bare... longitudinal and vertical acceleration experienced by the race car at the center of gravity (CG) during skid pad event 292 2) Acceleration and Brake Test Graph 75-Longitudinal, associated lateral and. .. unsprung mass of the race car during acceleration and brake test 293 Graph 76-Longitudinal, associated lateral and vertical acceleration experienced by the front right unsprung mass of the race