Simulation

This was the first time in our team's history conducting a complete FEA simulation on the chassis. I was responsible for simulations covering the torsional stiffness, cornering, braking, and crashes to ensure sufficient FOS. This data is used to inform vehicle dynamics and handling performance.

Validation

The objective was to validate simulated torsional stiffness through real-world testing, ensuring results could be replicated across future spaceframes for consistent long-term comparison, all while keeping cost and manufacturability reasonable.

Two testing methods were considered: using front jacks with fixed rear supports to directly measure twist, and a more complex setup involving a scissors jack with load cell scales to simulate realistic weight transfer.

For SN4, the first method was selected due to its simplicity, cost-effectiveness, ease of replication, and compatibility with available equipment.

The physical testing yielded an average torsional rigidity of 980.33 Nm/deg, which was approximately 15.49% lower than the simulation results. This discrepancy can be attributed to several factors, including tolerance stackup in the fixture and chassis components, and human error during setup and measurement.