Finite Element Analysis And Optimization Design Of The Frame Structure Of FSAE Car

In order to exercise the ability of students using theoretical knowledge to develop the FSAE racing car,students in our university formed a FSAE racing car team to take part in the FSAE tournament in 2015.The function of the FSAE racing car frame is to support and connect all parts of the car,and to bear all kinds of loads from inside and outside the car,its static strength and stiffness directly affect the load bearing capacity of the frame and the car parts relative installation position on the frame,and then affect the car's handling stability.The vibration characteristic of the frame affects the dynamic performance of the car.In this paper,a new frame(new frame)was designed by using topology optimization technology.The strength and stiffness of the initial frame(which was designed by FSAE racing car team relying on the competition requirements and the excellent teams' design experience)and the new frame structure were analyzed and compared,and the modal analysis of the new frame system was analyzed.The main research work was as follows:(1)The Hyper Works/OptiStruct module was used to build the topology optimization model,then the topological structure could be obtained by topology optimization design.The frame structure was designed according to the frame structure requirements of competition rules and the assembly requirements of the body parts.(2)Using ANSYS numerical simulation software,equivalent static strength simulation analysis of the initial frame and the new frame with full load in driving bending conditions,braking conditions and bending and torsion conditions were conducted,torsion and bending stiffness simulation analysis were also conducted.According to the analysis and comparison of the initial frame and the new frame of the static performance and quality,it could get the result that the static performance of the new frame was better than that of the original frameand the weight of the new frame was lighter,and met the requirements of static performance.(3)Modal analysis of the new frame systems were conducted,there were the free modal analysis of the free frame,the modal analysis of the “suspension-frame” system,the“frame-load” system and the “suspension-frame-load” system.The influence of frame structure,suspension spring and frame load on the dynamic performance of the whole frame system was analyzed.The analysis result provided the theory basis of improvement of the frame structure to avoid resonance.The results show that the frame system can avoid the occurrence of low frequency resonance,and the influence of higher frequency local vibration can be neglected,the frame meets the requirement of dynamic performance.According to the analysis result,the local structure of the new frame has been modified and has been adopted by the FSAE racing car team.Our school FSAE racing car team have gone to Shanghai to participate in the 2015 FSAE tournament and the design report of the FSAE racing car has obtained ninth grades.