Mec 603

Finite Element Method

Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

1.0 Introduction

The Formula car is a form of open-wheel race car that has evolved from the early 1900s Grand Prix
cars. Although the most well-known forms are Formula One and Indycar, formula cars have been a
staple of amateur motorsports, especially as a stepping stone to these top level series.

Modern amateur cars are characterized by their scratch-built single seat chassis, mid-engine rear-
drive layout and aerodynamic bodywork. Winged formula cars use inverted wings at the front and rear
of the car to provide down force that presses the car down onto the track at speed. This enables them to
corner at speeds much higher than standard road cars.

Amateur racing classes for formula cars generally focus on designs which use a space frame
chassis, 4 to 6 cylinder car or motorcycle engine, and fiberglass or aluminium plate bodywork. The
chassis is relatively easy to construct and repair and the engine is reasonably low cost to maintain.

Racing is generally on road course circuits and is therefore most popular in parts of Europe and
the Americas where road course circuits are found.

Finite Element Analysis is widely accepted in almost all engineering disciplines. The method is
often used as an alternative to the experimental test method set out in many standards. The technique is
based on the premise that an approximate solution to any complex engineering problem can be reached
by subdividing the structure/component into smaller more manageable (finite) elements. The Finite
element analysis is preferable to be used because of the complicated structure. Furthermore, it reduce
the time of development and improved safety of the structure.

1 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

2 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

2.0 Objective
The objective of doing this task are :

1. To develop Finite Element Model of single seated car

2. To obtain the stress and displacement analysis of the car frame for certain cases.
3. To optimise the car frame design if the stress analysis are over the yield strength of the
material.

3.0 Problem Description

General chassis configuration of a single seater race car is shown below. Tubular structure (Ro = 11, Ri
= 10) is made of steel (E = 200GPa, Sy = 220MPa), while the plate (t = 1) are made of aluminium (E =
70GPa, Sy = 220MPa). Using the shown dimensions, perform strength and displacement analysis for
the following cases:

1. Straight line drive at 3g downward acceleration.

2. A 4 m radius turn at 30km/hr

If the sizes of the plate and tubes are not providing safety of structures (observe the yield strengths and
max dispacment no more than 2mm), provide different sizes as required. Engine + transmission mass is
assumed to be 50Kg, 20Kg of fuel, driver 75Kg, and steering, mechanishm linkage of 20kg.

3 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

4.0 Finite Element Model

Type of Element

There 2 type of element use in the finite element model:

1. Beam
a. Tubular structure
b. Material =steel ( E=200GPa, Sy=220MPa )
c. Dimension;
i. Ro = 11mm
ii. Ri = 10mm

2. Shell
a. Plate
b. Material = Aluminium ( E=70GPa, Sy=220MPa )
4 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

c. Dimension;
i. t = 1mm

5 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

List of Node and Dimension in Coordinate

Unit: meter

LIST ALL SELECTED NODES. DSYS= 0

SORT TABLE ON NODE NODE NODE

NODE X Y Z THXY THYZ THZX

1 0.0000 0.0000 0.50000 0.00 0.00 0.00
2 0.0000 0.0000 0.0000 0.00 0.00 0.00
3 0.60000 0.0000 0.65000 0.00 0.00 0.00
4 0.60000 0.0000 -0.15000 0.00 0.00 0.00
5 1.2000 0.0000 0.65000 0.00 0.00 0.00
6 1.2000 0.0000 -0.15000 0.00 0.00 0.00
7 1.8000 0.0000 0.65000 0.00 0.00 0.00
8 1.8000 0.0000 -0.15000 0.00 0.00 0.00
9 0.10000 0.0000 -0.25000E-01 0.00 0.00 0.00
10 0.50000 0.0000 -0.12500 0.00 0.00 0.00
11 0.10000 0.0000 0.52500 0.00 0.00 0.00
12 0.50000 0.0000 0.62500 0.00 0.00 0.00
13 1.4000 0.0000 0.65000 0.00 0.00 0.00
14 1.6000 0.0000 0.65000 0.00 0.00 0.00
15 1.4000 0.0000 -0.15000 0.00 0.00 0.00
16 1.6000 0.0000 -0.15000 0.00 0.00 0.00
17 0.0000 0.40000 0.0000 0.00 0.00 0.00
18 0.0000 0.40000 0.50000 0.00 0.00 0.00
19 0.60000 0.40000 -0.15000 0.00 0.00 0.00
20 0.60000 0.40000 0.65000 0.00 0.00 0.00

NODE X Y Z THXY THYZ THZX

21 0.10000 0.40000 -0.25000E-01 0.00 0.00 0.00
22 0.50000 0.40000 -0.12500 0.00 0.00 0.00
23 0.10000 0.40000 0.52500 0.00 0.00 0.00
24 0.50000 0.40000 0.62500 0.00 0.00 0.00
25 0.60000 0.60000 0.65000 0.00 0.00 0.00
26 0.60000 0.60000 -0.15000 0.00 0.00 0.00
27 1.2000 0.60000 -0.15000 0.00 0.00 0.00
28 1.2000 0.60000 0.65000 0.00 0.00 0.00
29 1.5000 0.60000 0.65000 0.00 0.00 0.00
30 1.5000 0.60000 -0.15000 0.00 0.00 0.00
31 1.2000 0.40000 0.65000 0.00 0.00 0.00
32 1.2000 0.40000 -0.15000 0.00 0.00 0.00
33 1.4000 0.40000 0.65000 0.00 0.00 0.00
34 1.6000 0.40000 0.65000 0.00 0.00 0.00

6 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

35 1.4000 0.40000 -0.15000 0.00 0.00 0.00

36 1.6000 0.40000 -0.15000 0.00 0.00 0.00
37 1.2000 0.75000 0.0000 0.00 0.00 0.00
38 1.2000 0.75000 0.50000 0.00 0.00 0.00
39 1.2000 0.90000 0.15000 0.00 0.00 0.00
40 1.2000 0.90000 0.35000 0.00 0.00 0.00

NODE X Y Z THXY THYZ THZX

41 0.90000 0.0000 -0.15000 0.00 0.00 0.00
42 0.60000 0.0000 0.25000 0.00 0.00 0.00
43 0.90000 0.0000 0.25000 0.00 0.00 0.00
44 0.90000 0.0000 0.65000 0.00 0.00 0.00
45 1.2000 0.0000 0.25000 0.00 0.00 0.00

7 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

Finite Element Model

0.3

0.1
0.9

0.6 0.6
1.8

0.
2

0.
0. 0.

0.

Fix Point

8 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

Total fix point in the structure are 10 point.

These point are define as fix point because its
connected to the tyre which is land on the
road. 2 point for each front tyre and 3 point for
each rear tyre.

9 | Page
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

List of Force

1st case: Straight line drive at 3g downward acceleration.

The load on each node are calculated by the weight of the object time 3 times of gravity.

Node load = (weight load x 3(-9.81)) / no. of node involve

No Load No. Node Load at each node (FY axis)

.
1. Structure 44 -40.13N
2. Transmission and Engine 6 -245.25 + -40.13 = -285.38N
3. Fuel 4 -147.15 + -40.13 = -187.28N
Steering 4 -147.15 + -40.13 = -187.28N
Driver 8 -245.29 + -40.13 = -285.42N
1 -245.29N

10 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

11 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

2nd Case: A 4 m radius turn at 30km/hr.

The load in the case 1 still use in this case. However, when take a corner there is an additional force
acting toward the center of the radius turn.

Formula use: mv2/r

No Load No. Node Load at each node (FZ axis)

.
1. Structure 44 -23.67N
2. Transmission and Engine 6 -144.67 + -23.67 = -168.34N
3. Fuel 4 -86.8 + -23.67 = -110.47N
Steering 4 -86.8 + -23.67 = -110.47N
Driver 8 -144.67 + -23.67 = -168.34N
1 -144.67N

12 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

13 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

4.0 Result and Discussion

1st case: Straight line drive at 3g downward acceleration.

Displacement:

Beam Max. Displacement: 0.252mm

Shell Max. Displacement: 0.757mm

14 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

The maximum displacement of the shell element is 0.757mm at the center aluminium plate at
the driver seat area. The maximum displacement of beam element is 0.252mm at the tubular structure
connected to the aluminium plate of driver seat. The size of plate and tubes are providing safety
structures. Both maximum displacement of the shell and beam element does not even close to the
maximum allowable displacement state in the question which is 2mm.

15 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

Von Misses Stress:

Beam Max Stress: 19.3MPa

Shell Max Stress: 4.28MPa

16 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

The maximum Von Mises Stress of the shell element is 4.28MPa. The side aluminium plate
place between the front suspension node and steering. The maximum Von Misses Stress of beam
element is 19.3MPa. The position is at 0.6m from front of the tubular structure. The node that have
driver, steering, mechanism, and linkage load acting on. The size of plate and tubes are providing safety
structures. Both maximum Von Mises Stress of the shell and beam element does not even close to the
yield strength for both material which is 220MPa.

17 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

2nd Case: A 4 m radius turn at 30km/hr.

Displacement:

Beam Max. Displacement: 0.757mm

Shell Max. Displacement: 0.757mm

18 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

The maximum displacement of the shell element is still 0.757mm at the center aluminium plate
at the driver seat area. The maximum displacement of beam element is 0.757mm at change place from
the tubular structure connected to the aluminium plate of driver seat for the first case to tubular
structure at back of the frame at the engine and transmission mounting node. The size of plate and tubes
are still provide safety structures. Both maximum displacement of the shell and beam element does not
even close to the maximum allowable displacement state in the question which is 2mm.

19 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

Von Misses Stress:

Beam Max Stress: 40.2MPa

Shell Max Stress: 0MPa

20 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

The maximum Von Mises Stress of the shell element for the second case are unable to be
determined. There are no change of element colour found. However the beam element that containing
the shell element are having stress between 13.4MPa to 17.9MPa. The maximum Von Misses Stress of
beam element is 40.2MPa. The position is at rear of the frame structure. To be more specific, the
maximum stress found are at fuel mounting node. Both maximum Von Misses Stress of the shell and
beam element does not even close to the yield strength for both material which is 220MPa.

21 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

5.0 Conclusion

In a nutshell, the finite element model is developed and undergoes stress and displacement analysis for
straight line drive at 3g downward acceleration and 4 m radius turn at 30km/hr. cases. There are no
need for changing of material size since the maximum stress and displacement for the frame analysis
are not over 2mm and 220MPa.

6.0 References
Barnett, A. (2016, March 23rd ). Introduction to finite element analysis. Retrieved from
OpenLearn: http://www.open.edu/openlearn/science-maths-
technology/introduction-finite-element-analysis/content-section-1.2
Formula (Winged). (2016, 12 15). Retrieved from Build Your Own Race Car! REsources for
the amateur car designer and builder:
http://www.buildyourownracecar.com/racecartype-formula-winged/
Hicks, D. S. (n.d.). FINITE ELEMENT ANALYSIS What is it and how can it help your
company? Retrieved from HERA Innovation in Metals: http://www.hera.org.nz

22 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
 Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

7.0 Appendix

List Nodal Forces for Selected Nodes

LIST NODAL FORCES FOR SELECTED NODES 1 TO 45 BY 1
CURRENTLY SELECTED NODAL LOAD SET= FX FY FZ MX MY MZ

NODE LABEL REAL IMAG

1 FY -40.1300000 0.00000000
1 FZ -23.6700000 0.00000000
2 FY -40.1300000 0.00000000
2 FZ -23.6700000 0.00000000
3 FY -285.420000 0.00000000
3 FZ -168.340000 0.00000000
4 FY -285.420000 0.00000000
4 FZ -168.340000 0.00000000
5 FY -285.420000 0.00000000
5 FZ -168.340000 0.00000000
6 FY -285.420000 0.00000000
6 FZ -168.340000 0.00000000
7 FY -40.1300000 0.00000000
7 FZ -23.6700000 0.00000000
8 FY -40.1300000 0.00000000
8 FZ -23.6700000 0.00000000
9 FY -40.1300000 0.00000000
9 FZ -23.6700000 0.00000000
10 FY -40.1300000 0.00000000
10 FZ -23.6700000 0.00000000

NODE LABEL REAL IMAG

11 FY -40.1300000 0.00000000
11 FZ -23.6700000 0.00000000
12 FY -40.1300000 0.00000000
12 FZ -23.6700000 0.00000000
13 FY -285.380000 0.00000000
13 FZ -168.340000 0.00000000
14 FY -40.1300000 0.00000000
14 FZ -23.6700000 0.00000000
15 FY -285.380000 0.00000000
15 FZ -168.340000 0.00000000
16 FY -40.1300000 0.00000000
16 FZ -23.6700000 0.00000000
17 FY -40.1300000 0.00000000
17 FZ -23.6700000 0.00000000
23 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

18 FY -40.1300000 0.00000000
18 FZ -23.6700000 0.00000000
19 FY -187.280000 0.00000000
19 FZ -110.470000 0.00000000
20 FY -187.280000 0.00000000
20 FZ -110.470000 0.00000000

24 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

NODE LABEL REAL IMAG

21 FY -40.1300000 0.00000000
21 FZ -23.6700000 0.00000000
22 FY -187.280000 0.00000000
22 FZ -110.470000 0.00000000
23 FY -40.1300000 0.00000000
23 FZ -23.6700000 0.00000000
24 FY -187.280000 0.00000000
24 FZ -110.470000 0.00000000
25 FY -40.1300000 0.00000000
25 FZ -23.6700000 0.00000000
26 FY -40.1300000 0.00000000
26 FZ -23.6700000 0.00000000
27 FY -40.1300000 0.00000000
27 FZ -23.6700000 0.00000000
28 FY -40.1300000 0.00000000
28 FZ -23.6700000 0.00000000
29 FY -187.280000 0.00000000
29 FZ -110.470000 0.00000000
30 FY -187.280000 0.00000000
30 FZ -110.470000 0.00000000

NODE LABEL REAL IMAG

31 FY -40.1300000 0.00000000
31 FZ -23.6700000 0.00000000
32 FY -40.1300000 0.00000000
32 FZ -23.6700000 0.00000000
33 FY -285.380000 0.00000000
33 FZ -168.340000 0.00000000
34 FY -285.380000 0.00000000
34 FZ -168.340000 0.00000000
35 FY -285.380000 0.00000000
35 FZ -168.340000 0.00000000
36 FY -285.380000 0.00000000
36 FZ -168.340000 0.00000000
37 FY -187.280000 0.00000000
37 FZ -110.470000 0.00000000
38 FY -187.280000 0.00000000
38 FZ -110.470000 0.00000000
39 FY -40.1300000 0.00000000
39 FZ -23.6700000 0.00000000
40 FY -40.1300000 0.00000000
40 FZ -23.6700000 0.00000000

NODE LABEL REAL IMAG

25 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058
Mec 603
Finite Element Method
Sem SEP DEC 2016
Faculty of
Mechanical
Engineering
University of
Technology Mara
40450 Shah Alam,
Selangor

41 FY -285.420000 0.00000000
41 FZ -168.340000 0.00000000
42 FY -285.420000 0.00000000
42 FZ -168.340000 0.00000000
43 FY -245.290000 0.00000000
43 FZ -144.670000 0.00000000
44 FY -285.420000 0.00000000
44 FZ -168.340000 0.00000000
45 FY -285.420000 0.00000000
45 FZ -168.340000 0.00000000

26 | P a g e
ABDUL LATIP BIN ABD WAHAB 2014607678
MOHD NURAMIRUL AKMAL BIN ZAINURI 2014839058