Warwick Racing Chassis Project – jamalpatel

Warwick Racing Chassis project for Formula Student Car

The Project:

Nose Cone Structure:

Responsible for designing the floowing and nose of the Warwick WRe2 Formula Student Race Car to the necessary safety standards and to a high quality.

3D design of the components behind the nose was required and this was achieved using both Autodesk Fusion 360 and AutoCad software.

The nose design consisted on the nosecone (black), impact attenuator, anti-intrusion plate brackets and the anti- intrusion plate all of which are connected the the front tubular chassis structure via suitable fixtures.

Design and Development

The Anti-Intrusion Plate and its brackets were all designed on Fusion 360 and cut out of a Aluminium sheet via a DXF file that was downloaded to a waterjet. This ensured significant precision in its design.

A roller bender was used to bend the ends of the brackets to the necessary angle such that it can facilitate the impact attenuator and nose cone structures.

Nose cone was 3D printed using LCP (Liquid Crystal Polymer) due to its high durability making suitable for formula student competition.

These structures were all connected using M8 screws held via nuts and washers as shown below.

Flooring:

Decision was made to use aluminium for the flooring due to its lightweight properties as well as ease of cutting using a waterjet.

Due to the way the chassis tubular structure was designed, the floowing would be composed of 3 separate components all of the same depth and material.

The flooring would be secured to the structure using gussets which have 6mm holes, in which an m6 bolt would pass through.

To create these holes on the flooring panels, a pillar drill would be used to create a hole through the necessary area of the flooring panels which was traced below the car when positioned above the gussets and in the chassis tubular structure.

The Project Final Result:

The project yielded successful development of the nose cone structure and flooring of the WRe2 race car.

Design and development also gave me insight into the various barriers and challenges that would occur in producing these components such as tolerance and fitment to meet the necessary regulations, putting an emphasis on the problem-solving skills needed in an engineering environment.

Opportunities to work on other various Warwick Racing projects such as the suspension and vehicle dynamics also opened up, allowing for insight into the engineering behind these components. For example, I was able to help the suspension team in preparing the suspension gussets which were necessary to connect certain suspension components such as the wishbones as well as work on connecting the headrest for the cockpit to the chassis.

Flooring structure

Anti-Intrusion Plate and Brackets structure

Nose Cone and Attenuator Structure

Nose Cone assembly

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