| The 2008 Cooper Union Formula SAE team built off the success of the 2007 competition season by redesigning the vehicle subsystems, learning from the mistakes in design and manufacturing of the previous season, and developing a structured framework of design, analysis, and iteration. This thesis documents the design, analysis, and manufacturing process of the frame system, along with the integration and manufacturing of the remaining subsystems. Finite Element Analysis (FEA) Simulations were conducted on the frame system to simulate real-world dynamic events to optimize the frame design and to ensure its structural integrity. This thesis will serve as the foundation to individuals looking to pursue the design of the Formula SAE vehicle frame or similar project. This thesis also investigates the design process, balancing goals of the design with manufacturing and financial compromise. This thesis will continue to stress the importance of supporting subsystems such as the suspension system and engine system and further investigate validation of the analysis models through a structured testing procedure. Lastly, the results and lessons learned from the 2008 competition season at Virginia International Raceway and Michigan International Speedway will be documented. The purpose of this thesis is to inform future Formula SAE teams of the design and manufacturing process in order to streamline future vehicle production in a structured and method. |
