Formula 1000 Frame Design

Kimo “Kokonuts” SpectorDavid “Deuce” McMahonMatthew “McLovin” DiasioTomas “T-Bird” Lafferriere

Daniel “Fat Dan” Rist

Formula 1000 Class

Closest amateur competition to Formula One

Single-person, Open-wheel, Open-cockpit design

Powered by a 1000cc motorcycle engine

Chassis must be made of steel Minimum racing weight of 1000 lbs. Governed by the SCCA (Sports Car

Club of America)

Chassis Design

Monocoque design were used through 1950’s

Space Frame began growing in popularity in late 1960’s

Space Frame a low cost, lightweight, easy to maintain chassis

Now used mainly in Amateur Racing

Our Chassis

Steel tube space frame design Tube size specified by SCCA rulebook

(AISI 4130) Raised nose design for improved

aerodynamics Allows for the use of a full width wing

Comprised of Pratt & Town’s lattice trusses

3D Frame Model

Cost of Materials

AISI 4130 is standard material for automotive frames

Approximately $8 per foot SolidWorks gives frame volume

Need to find length Divided volume by cross-sectional area

of tube 177.8 ft of tube = $1,422.40 per

chassis

Other Cost Factors

Welding $75 per hour 40 man-hours to complete $3000 for labor per chassis

Worst-case scenario: need 12 frames a year Assume that team orders 185 ft of tube

per chassis (materials cost $1,480 per chassis)

$53,760 to make 12 chassis a year

Testing Parameters

First test was simulated rollover onto main hoop

Other tests simulated impact with another F1000 car from various angles

Weight assumed to be minimized to 1000 lbs

Speed of 60 mph consistent with corner exit speed of a F1000 car

Used a collision time of 0.1 seconds Used time derivative change in momentum

to calculate equivalent force

Inconsistencies

Simulates direct impact on frame Body would absorb some of impact

Used fixed geometry restraints at wheel attachments Impacts would cause the car to slide Sliding would dissipate a great deal of the

energy from the impact. Also assumes velocity of impacting car

goes to zero, absolute worst case scenarios

Simulation Analysis

Roll-bar test required by SCCA Frame experiences maximum

displacement of .0855 in.

Stress Analysis

Impact at cross point of cabin truss results in most displacement

6.664 in. of predicted displacement All other tests result in less than 1.6

in. of displacement

Stress Analysis

Simulated front impact by removing first four fixed supports

Deformation of less than an inch