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AEROSPACE AND MOTORSPORT METALSRoll Cage and Chassis Tubing specialistssupporting Formula Student RacingGeneRAl & SAleS enqUiRieS02476 645 551formulastudent@aerocommetals.co.ukCHASSIS & ROLL CAGE TUBINGAs a key stockholder in the supply of motorsport materials, over the last few yearsAerocom Metals has focused its attention on roll cage tubing. We have utilised ourcombined experience and expert knowledge of both material properties and the guidelinesset down by the sports different governing bodies. From the home builder to theprofessional teams, off the shelf tubing to bespoke branded products we firmly believe weare the market leaders. Recently aiding the success of UBRacing Birmingham and OxfordBrookes, we are now focusing on supporting Formula students, offering discounts to teamson our entire stock range.NOWSTOCKINGAluminium>> 7075>> 7050>> 6061>> 6082>> 5052>> 2024Alloy>> 4130>> 4140>> 4340>> 4330>> 300M>> T45BS4T45 to BS5T100Aerocom Metals are now THE stockists for BS4T45 to BS5T100 with over 40sizes available off the shelf. We have worked hard to support and promotethis unique British product. Turn over to view our full stock range >>>Stainless>> 13/8>> 17/4>> 15/5Titanium>> 6al4v>> 6al4v Eli>> CP 4,3,2,1www.aerocommetals.co.uk
TECHNOLOGY – TUBULAR FRAMESPerfecting thespaceframe chassisIt's been written that the spaceframe chassis has been optimised.It hasn’t, says one former Coventry University studentThe hybrid spaceframe has atorsional rigidity of 4,450Nm,which is over four times greaterthan the steel spaceframe that itwas designed to replace. Therewere negligible weight savingsdue to constraints on materialdimensions, although the specificstrength of a hybrid spaceframeis significantly higherThe tubular steel chassisis not fashionableany more. These daysalmost every youngengineer wants to use advancedcomposite materials like carbonfibre to design their new car.They even turn their noses upat the use of a tubular chassis.They argue that steel chassisare heavy, lack rigidity andare not as safe as compositemonocoques. Those in favour ofthe tubular steel chassis arguethat the ‘spaceframe’ is cheap,easy to manufacture, easy torepair and highly versatile.But one student at CoventryUniversity in England wonderedif it would be possible to getthe best of both worlds.Replicating the thoughts of manylow-cost formula car designersover the years, such as thosebehind the British-built RossaliniFV391 Formula Vee, could hereplace at least some of thesteel with readily availablecomposite tubing?Giorgio Demetriou tookhis university’s 2012 FormulaStudent car design (a steeltube frame) and investigatedconverting the design into whathe calls a hybrid spaceframe. Theresults are relevant to anyonedesigning or building cars in anopen rules environment, such asFormula Ford, Vee or a numberof SCCA classes.‘I aimed to develop a chassiswhich is competitive withcomposite monocoques usedin Formula Student, but whichcould be manufactured forsubstantially less cost in ashorter timeframe,’ explainsDemetriou. ‘I realised quicklythat there were two key pointsto address: the use of tubularcarbon fibre in spaceframeconstruction and the applicationof direct metal laser sinteringas a manufacturing process tocreate connection nodes.’One of the key points of theproject was that Demetriou andthe other Coventry studentsdid not want to modify theexisting design in any way,leaving the hard points andgeometries as they were.‘Spaceframes have been usedfor many decades, and as a resultmuch research and testing hasgone into the optimised design.An ideal framework would consistof only struts and ties, pin jointedand loaded at the joints,’ addsDemetriou. ‘It could be arguedthat tubular chassis design hasbeen completely optimised,and literature has been writtento this effect. The design of aspaceframe chassis is unique toeach vehicle and each will pose anew set of packaging constraints.A good spaceframe will receiveTable 1: carbon tube selectionTube Material OD Wall ThicknessBaseline 1 Steel 25.4mm 1.6mmBaseline 2 Steel 25.4mm 1.25mmReplacement 1 CFRP 28mm 1.84mmReplacement 2 CFRP 26mm 1.56mmFormula Student supplement • www.racecar-engineering.com
Page 1 and 2: Leading-Edge Motorsport Technology
Page 3: CONTENTS - FORMULA STUDENT EDITIONS
Page 7 and 8: front suspension operated alongan a
Page 9 and 10: TECHNOLOGY - TUBULAR FRAMESthe Cove
Page 11 and 12: TECHNOLOGY - AEROBYTESStudents unle
Page 13 and 14: Tip vortices created the usual fasc
Page 15 and 16: completed minimal testing, andthose
Page 17 and 18: OVERALL WINNER: ETH ZuRIcHThis year
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Page 27 and 28: the quality of the students atCranf
Page 29 and 30: ENGINEERING EXCELLENCETHROUGH INTEL
Page 31 and 32: TECH DISCUSSIONSave Formula Student

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