Journal of Aeronautical and Automotive Engineering (JAAE) p-ISSN: 2393-8579; e-ISSN: 2393-8587; Volume 3, Issue 1; January-March, 2016 pp. 26-32 © Krishi Sanskriti Publications http://www.krishisanskriti.org/Publication.html Design and Analysis of Formula SAE Chassis Srishti Shukla 1 , Shubh Agnihotri 2 and R. R. Sahoo 3 1,2 B.Tech Part-II Department of Mechanical Engineering I.I.T. (B.H.U.), Varanasi 3 Department of Mechanical Engineering I.I.T. (B.H.U.), Varanasi E-mail: 1 srishti.shuklacd.mec14@itbhu.ac.in, 2 shubh.agnihotri.mec14@itbhu.ac.in, 3 rrs_iitbhu@rediffmail.com Abstract—The design of formula chassis [9] involves optimization between more performance parameters than other automobile chassis types. Besides achieving high torsional stiffness and strength, an efficient design should accommodate weight reduction and ease of manufacturing. This paper introduces a torsionally, laterally and longitudinally stiff chassis design, which has been drafted ergonomically to accommodate anthropomorphic models of the tallest (95th percentile male) and the smallest (5th percentile female) driver. Binocular visions for the entire range of drivers were simulated to ensure sufficiently large domain of vision for them. A variety of materials were considered and a comprehensive comparison was drawn amongst the material properties to select the material which could settle with the structural requirements. Hence the design was thoroughly analyzed, through simulation for the various load distributions that a Formula SAE car may encounter and subsequent deformations. This paper also introduces the design of a crumble zone, and an equally comprehensive structure and material selection for impact attenuator design. The torsional rigidity calculated for the model was 4026.785 Nm/deg and the minimum factor of safety obtained amongst all load distributions was 9.16 for a weight of 55.78kg. In this context, it is obligatory to mention that though the chassis design developed corresponds with the rules of Formula SAE, the engineering aspects of the conditions specified in the rules have also been thoroughly explored to induce maximum augmentation in structural strength and rigidity. 1. INTRODUCTION Generally formula one cars are designed to withstand 3.5 g bump, 1.5 g braking and 1.5 g lateral forces [3]. Fig. 1.1: Forces encountered by an FSAE car 1.1 Structural requirements of Formula chassis  Should be strong enough to protect the driver from external intrusion.  Torsional stiffness should be enough to avoid angular flexing.  Chassis should be rigid enough to avoid longitudinal and lateral flexing [2].  Rigidity is also important to maintain precise control over suspension geometry, i.e. to maintain contact between the wheels and race road surface.  Light Weight  Exhibiting proper safety factors 1.2 Crumple Zone The crumple zone [8] (also called crush space) is a structural feature mainly used in automobiles and recently incorporated into railcars. Crumple zones are designed to absorb the energy from an impact by deforming. They are usually placed at the front and rear of a car as these are the locations of most impacts. The ability of a crumple zone to collapse when a force is applied to it helps to increase the time taken for the vehicle to come to a complete stop. Since acceleration is inversely proportional to time, increasing the time taken causes the magnitude of deceleration of the vehicle to be reduced. The crumple zone is designed to reduce the magnitude of deceleration of a vehicle, so that the force exerted on the vehicle is also reduced. 2. THEORETICAL MODELLING AND SIMULATION 2.1 Selection of Space Frame Chassis For the following reasons, space frame chassis was selected –  Ladder frame structure could not be selected because of lack of diagonal bracing, because of which it can easily be twisted along its length. For making the chassis more stiff and more rigid, extra members have to be added which in