MATERIAL SELECTION

Low Carbon Steel

™Heavy but strong, with a potential infinite fatigue life

™Easy to weld and needing no special heat treatments

™Inexpensive and readily available ‘of the shelf’ in a large

range of sizes, though some of the less popular sizes are
only available on special order
™Though prone to rust, low carbon steel is easily painted,
and with the correct coating choice, is easily and
successfully repaired
MATERIAL PROPERTIES

AISI 1020 DOM 350

z It is considerably cheaper
z It is easy to weld and form
z Repairs/modifications can safely be done
z Can be easily painted in wide range of colors
FINAL DESIGN CONCEPTUAL
FRONT VIEW & BACK VIEW
SIDE VIEW
TOP VIEW
DIMENSION OF CHASSIS – FRONT VIEW
DIMENSION OF CHASSIS – SIDE VIEW
DIMENSION OF CHASSIS – TOP VIEW
ORTOGRAPHIC DRAWING
CHASSIS TOTAL WEIGHT

CALCULATION OF CHASSIS MASS

•Using solid edge physical properties calculations

•Manual calculations using density and total volume

USING 1ST METHOD
USING 2ND METHOD
z Density = 7860 kg/m3
z Mass = Density x Volume
z Volume = Surface area x Length of the tube
z Surface area = π /4 ( D2 – d2 )
z Volume = π /4 ( 2.542 – 2.062 ) x L
z Total length = 3680 cm

Manual Calculation

z Mass = 7.86 ( 1.734 ) cm2 / cm3

= 13.63 gram for 1 cm length
z Total Mass = 13.63 x 3680
= 50158.7 gram @ 50.159 kg
z Total Mass = 50.159 kg
CALCULATION OF STATIC & DYNAMIC
Assumption of load distribution in the chassis

F Power
Train F Body

F Engine F Driver &

Sit

F Rear Wheel
F Rear
Left
Wheel Right
F Wheel
Left
F Wheel
Right
LOAD CALCULATIONS
z Force applied by engine & gearbox = 75 kg x 9.81
= 735.75 N
z Force applied by driver + sit = 90 kg x 9.81
= 882.9 N
z Force applied by power train = 20 kg x 9.81
= 196.2 N
z Force applied by radiator = 6 kg x 9.81
= 196.2 N
z Force applied by fuel tank = 12 kg x 9.81
= 117.72 N
z Force applied by body = 30 kg x 9.81
= 294.3 N
z Force applied by peripheral force = 36 kg x 9.81
= 351.16 N
z Force applied by tire & braking system = 80 kg 9.81
= 784.4 N
FORCE DISTRIBUTIONS

i. Engine & gearbox = Load produced by the engine + gearbox

load distribution 2 crossbars
= 735.75 / 2
= 367.875 N
ii. Power train load = Load produced by the power train
distribution 8 bolts
= 196.2 / 8
= 24.525 N
iii. Driver & Sit load = Load produced by the driver + sit
distribution 2 bolts
= 490.5 N
iv. Body work load = Load produced by body work
distribution 6
= 294.3 / 6
= 49.05 N