Tube Frame - Revision history

Emilyanthony: fix weird spacing issues

2024-08-11T17:33:19Z

fix weird spacing issues

Emilyanthony at 16:44, 29 August 2022

2022-08-29T16:44:50Z

Emilyanthony at 16:41, 29 August 2022

2022-08-29T16:41:57Z

Emilyanthony at 16:31, 29 August 2022

2022-08-29T16:31:41Z

Emilyanthony: /* Analysis */

2022-08-29T15:58:35Z

Analysis

Emilyanthony at 15:58, 29 August 2022

2022-08-29T15:58:09Z

Emilyanthony: /* Driver Accommodation and CAD basics in SolidWorks */

2022-08-29T15:56:43Z

Driver Accommodation and CAD basics in SolidWorks

Emilyanthony: /* Driver Accommodation and CAD basics in SolidWorks */

2022-08-29T15:56:13Z

Driver Accommodation and CAD basics in SolidWorks

Emilyanthony: /* Welding */

2022-08-29T15:55:28Z

Welding

Emilyanthony: spacing, spelling, grammar

2022-08-29T15:53:18Z

spacing, spelling, grammar

@@ Line 1: / Line 1: @@
 [[Category:Chassis]]
 A tube frame or space frame is a chassis constructed from rigid truss members attached in a three-dimensional structure with the body panels having little or no structural function. Stiffness is maximized by triangulating the tubing to ensure that the tubes are not loaded in bending.
 ==Required Reading==
@@ Line 16: / Line 11: @@
 * Chassis Design: Principles and Analysis Milliken 0768008263.
 * Dodd, C. et al, "MEEG 402-010 Chassis Design Report". 2017 https://udel.edu/~pgeneva/downloads/fsae/2017_FSAE_chassis.pdf. ("The Delaware Paper")
 ==Design Considerations for Systems Integration==
@@ Line 45: / Line 38: @@
 As part of smart CAD practice, it is best to have a "master sketch" (or a few in this case due to the complexity) such that the entire frame design is controlled at the top of the part tree, and so that you don't have to go to 10 different features just to make one change. Learn to work with [https://help.solidworks.com/2019/english/SolidWorks/sldworks/t inserting_reference_dimensions.htm driven dimensions], and construction geometry. 3D sketches are computationally difficult, so you may occasionally see weird bugs with things going over defined even though they shouldn't. To mitigate this, reduce the number of dimensions and sketch lines per 3D sketch.
 ====Example Layout====
@@ Line 85: / Line 76: @@
 " to produce their tube set.They will bend and cope tubes for the team in the $3000-5000 range for frame and suspension, depending on complexity and shipping. VR3 has strict requirements on documentation sent to their sales engineers and is detailed on their website at<a href="https://vr3.ca/request-a-quote/">https://vr3.ca/request-a-quote/.</a>
 ===In-house Fabrication===
@@ Line 94: / Line 82: @@
 ====Tube bending====
 Manual Bending
 CNC Bending
 ===Fixtures===
 Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum]
 . From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).
 (Fixture gallery?)
 ===Welding===
@@ Line 123: / Line 99: @@
 ==Analysis==
 Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in SolidWorks]]
 * To test torsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity

@@ Line 33: / Line 33: @@
 [[File:Image159.png|center|middle|thumb|Driver Sketch ]]
 with a separate sketch building up the Side view frame around it:
-[[File:Image80.png|center|middle|thumb|Driver Sketch and Side View Frame ]]<a class="image"><img alt="" src="/images/thumb/f/f9/Image80.png/300px-Image80.png" decoding="async" width="300" height="182" class="thumbimage" srcset="/images/thumb/f/f9/Image80.png/450px-Image80.png 1.5x, /images/thumb/f/f9/Image80.png/600px-Image80.png 2x"></a>  <a class="internal" title="Enlarge"></a>Driver Sketch and Side View Frame
+[[File:Image80.png|center|middle|thumb|Driver Sketch and Side View Frame ]]
 The frame CAD is best set up with the help of both 2D and 3D sketches, and then with the use of "[https://help.solidworks.com/2021/English/SolidWorks/sldworks/c Weldments_Overview.htm Weldments]" - basically pre-configured sweep features, that are generated on top of the sketches (the sketch being the neutral axis of the tube). It makes things quite easy to make, and to export later - SolidWorks generates a "cut list": a BOM of tubes.
 Teams may be required to create or import [https://help.solidworks.com/2020/English/SolidWorks/sldworks/t Weldments_Creating_a_Custom_Profile.htm custom weldment profiles].
 As part of smart CAD practice, it is best to have a "master sketch" (or a few in this case due to the complexity) such that the entire frame design is controlled at the top of the part tree, and so that you don't have to go to 10 different features just to make one change. Learn to work with [https://help.solidworks.com/2019/english/SolidWorks/sldworks/t inserting_reference_dimensions.htm driven dimensions], and construction geometry. 3D sketches are computationally difficult, so you may occasionally see weird bugs with things going over defined even though they shouldn't. To mitigate this, reduce the number of dimensions and sketch lines per 3D sketch.
@@ Line 80: / Line 63: @@
-===<span style="font-size: 17.92px; font-weight: bold;">Triangulation</span><br />===
+==<span style="font-size: 17.92px; font-weight: bold;">Triangulation</span><br />==
 Proper triangulation makes sure that the tubes are not loaded in bending. Full triangulation is probably impossible given that the driver like, can't have a frame member through their torso, but please try?
 Note that because some tubes will inevitably take bending (primarily the side impact structure, due to impossible triangulation from the big empty space the driver occupies), there should be emphasis on reducing tube aspect ratio (by either upping diameter or reducing length), and adding gussets.
-===Tube Choice===
+==Tube Choice==
-====Alloys====
+===Alloys===
 [[Steel#1000 Series|10XX steel]]
 is cheap, easy to weld, readily available, and easy to machine.
 [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat might be required).
 ====Method====
 ERW, DOM
 ==Manufacturing==
 ===Outsourcing===
@@ Line 143: / Line 118: @@
 ===Welding===
 {{Main|Welding}}
 : Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference<ref>FSAE Rules. https://fsaeonline.com/cdsweb/gen/DocumentResources.aspx</ref>.
 ==Analysis==
-Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in solidworks]]
+Goal:[[File:Image152.png|right|middle|thumb|Torsional stiffness FEA in SolidWorks]]

@@ Line 7: / Line 7: @@
-Required Reading
+==Required Reading==
@@ Line 70: / Line 77: @@
 * Suspension (2D and 3D)
-[[File:Image167.png|center|middle|thumb|Front Tubes, with bulkhead and FRH visible]]<a class="image"><img alt="" src="/images/thumb/0/02/Image167.png/300px-Image167.png" decoding="async" width="300" height="200" class="thumbimage" srcset="/images/thumb/0/02/Image167.png/450px-Image167.png 1.5x, /images/thumb/0/02/Image167.png/600px-Image167.png 2x"></a>  <a class="internal" title="Enlarge"></a>Front Tubes, with bulkhead and FRH visibleIn-context relations deliver the suspension geometry to the a-arms, bellcranks, uprights, etc. That way, all adjustments to the geometry can be done in the frame file, and the changes would be up dated on assembly rebuild.[[File:Image107.png|center|middle|thumb|Suspension Integration into Frame file]]
+[[File:Image167.png|center|middle|thumb|Front Tubes, with bulkhead and FRH visible]]  <a class="internal" title="Enlarge"></a>Front Tubes, with bulkhead and FRH visibleIn-context relations deliver the suspension geometry to the a-arms, bellcranks, uprights, etc. That way, all adjustments to the geometry can be done in the frame file, and the changes would be up dated on assembly rebuild.[[File:Image107.png|center|middle|thumb|Suspension Integration into Frame file]]

@@ Line 1: / Line 1: @@
 [[Category:Chassis]]
@@ Line 5: / Line 7: @@
-==Design Considerations==
+Required Reading
 Designing the tube frame is a compromise between structural rigidity, weight, and manufacturing complexity while complying to the rules. One thing to remember is that the frame is basically a glorified bracket. From a systems perspective, the frame designer is primarily concerned with packaging the other vehicle components. In approximate order of importance:
 # Ergonomics
@@ Line 18: / Line 25: @@
 [[File:Image159.png|center|middle|thumb|Driver Sketch ]]
 with a separate sketch building up the Side view frame around it:
-[[File:Image80.png|center|middle|thumb|Driver Sketch and Side View Frame ]]
+[[File:Image80.png|center|middle|thumb|Driver Sketch and Side View Frame ]]<a class="image"><img alt="" src="/images/thumb/f/f9/Image80.png/300px-Image80.png" decoding="async" width="300" height="182" class="thumbimage" srcset="/images/thumb/f/f9/Image80.png/450px-Image80.png 1.5x, /images/thumb/f/f9/Image80.png/600px-Image80.png 2x"></a>  <a class="internal" title="Enlarge"></a>Driver Sketch and Side View Frame
@@ Line 37: / Line 46: @@
 As part of smart CAD practice, it is best to have a "master sketch" (or a few in this case due to the complexity) such that the entire frame design is controlled at the top of the part tree, and so that you don't have to go to 10 different features just to make one change. Learn to work with [https://help.solidworks.com/2019/english/SolidWorks/sldworks/t inserting_reference_dimensions.htm driven dimensions], and construction geometry. 3D sketches are computationally difficult, so you may occasionally see weird bugs with things going over defined even though they shouldn't. To mitigate this, reduce the number of dimensions and sketch lines per 3D sketch.
@@ Line 55: / Line 70: @@
 * Suspension (2D and 3D)
-[[File:Image167.png|center|middle|thumb|Front Tubes, with bulkhead and FRH visible]]In-context relations deliver the suspension geometry to the a-arms, bellcranks, uprights, etc. That way, all adjustments to the geometry can be done in the frame file, and the changes would be up dated on assembly rebuild.[[File:Image107.png|center|middle|thumb|Suspension Integration into Frame file]]
+[[File:Image167.png|center|middle|thumb|Front Tubes, with bulkhead and FRH visible]]<a class="image"><img alt="" src="/images/thumb/0/02/Image167.png/300px-Image167.png" decoding="async" width="300" height="200" class="thumbimage" srcset="/images/thumb/0/02/Image167.png/450px-Image167.png 1.5x, /images/thumb/0/02/Image167.png/600px-Image167.png 2x"></a>  <a class="internal" title="Enlarge"></a>Front Tubes, with bulkhead and FRH visibleIn-context relations deliver the suspension geometry to the a-arms, bellcranks, uprights, etc. That way, all adjustments to the geometry can be done in the frame file, and the changes would be up dated on assembly rebuild.[[File:Image107.png|center|middle|thumb|Suspension Integration into Frame file]]
 ===<span style="font-size: 17.92px; font-weight: bold;">Triangulation</span><br />===
@@ Line 65: / Line 87: @@
 ====Alloys====
 [[Steel#1000 Series|10XX steel]]
@@ Line 71: / Line 95: @@
 [[Steel#4000 Series|41XX steel]] is more expensive but stronger, more difficult to weld and machine (prone to cracking, heat treat might be required).
 ====Method====
@@ Line 76: / Line 105: @@
 ==Manufacturing==
 ===Outsourcing===
-Many teams in North America use "[https://vr3.ca/ VR3 Engineering]" to produce their tube set.They will bend and cope tubes for the team in the $3000-5000 range for frame and suspension, depending on complexity and shipping. VR3 has strict requirements on documentation sent to their sales engineers and is detailed on their website at<a href="https://vr3.ca/request-a-quote/">https://vr3.ca/request-a-quote/.</a>
+Many teams in North America use "[https://vr3.ca/ VR3 Engineering]
 ===In-house Fabrication===
@@ Line 90: / Line 125: @@
 ===Fixtures===
-Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum]. From the datum, important tubes should next be fixtured (suspension points, roll hoops, etc...).
+Fixtures (also known as jigs) indicate the location of tubes within the frame. Fixtures can be made of many materials. Fixtures should start measurement from a [https://en.wikipedia.org/wiki/Datum_reference datum]
 (Fixture gallery?)
@@ Line 100: / Line 142: @@
 ===Welding===
 {{Main|Welding}}
 : Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference<ref>FSAE Rules. https://fsaeonline.com/cdsweb/gen/DocumentResources.aspx</ref>.
 * To test torsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity

← Older revision		Revision as of 15:58, 29 August 2022
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	Goal:[[File:Image152.png\|right\|middle\|thumb\|Torsional stiffness FEA in solidworks]]		Goal:[[File:Image152.png\|right\|middle\|thumb\|Torsional stiffness FEA in solidworks]]
−
−
−	<a class="image"><img alt="" src="/images/thumb/0/0b/Image152.png/300px-Image152.png" decoding="async" width="300" height="176" class="thumbimage" srcset="/images/thumb/0/0b/Image152.png/450px-Image152.png 1.5x, /images/thumb/0/0b/Image152.png/600px-Image152.png 2x"></a> <a class="internal" title="Enlarge"></a>Torsional stiffness FEA in solidworks
−
−	<a class="image"><img alt="" src="/images/thumb/0/0b/Image152.png/300px-Image152.png" decoding="async" width="300" height="176" class="thumbimage" srcset="/images/thumb/0/0b/Image152.png/450px-Image152.png 1.5x, /images/thumb/0/0b/Image152.png/600px-Image152.png 2x"></a> <a class="internal" title="Enlarge"></a>Torsional stiffness FEA in SolidWorks
−

	* To test torsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity		* To test torsional rigidity, camber (lateral) rigidity, and perhaps also toe rigidity

← Older revision		Revision as of 15:58, 29 August 2022
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	[[File:Image159.png\|center\|middle\|thumb\|Driver Sketch ]]		[[File:Image159.png\|center\|middle\|thumb\|Driver Sketch ]]
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−	<img alt="" src="/images/thumb/2/22/Image159.png/300px-Image159.png" decoding="async" width="300" height="207" class="thumbimage" srcset="/images/thumb/2/22/Image159.png/450px-Image159.png 1.5x, /images/thumb/2/22/Image159.png/600px-Image159.png 2x" style="display: block; margin-left: auto; margin-right: auto;" data-mce-style="display: block; margin-left: auto; margin-right: auto;">
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	with a separate sketch building up the Side view frame around it:		with a separate sketch building up the Side view frame around it:

← Older revision		Revision as of 15:56, 29 August 2022
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−	~~<a class="image">~~<img alt="" src="/images/thumb/2/22/Image159.png/300px-Image159.png" decoding="async" width="300" height="207" class="thumbimage" srcset="/images/thumb/2/22/Image159.png/450px-Image159.png 1.5x, /images/thumb/2/22/Image159.png/600px-Image159.png 2x" style="display: block; margin-left: auto; margin-right: auto;" data-mce-style="display: block; margin-left: auto; margin-right: auto;"~~></a> <a class="internal" title="Enlarge"></a~~>	+	<img alt="" src="/images/thumb/2/22/Image159.png/300px-Image159.png" decoding="async" width="300" height="207" class="thumbimage" srcset="/images/thumb/2/22/Image159.png/450px-Image159.png 1.5x, /images/thumb/2/22/Image159.png/600px-Image159.png 2x" style="display: block; margin-left: auto; margin-right: auto;" data-mce-style="display: block; margin-left: auto; margin-right: auto;">

← Older revision		Revision as of 15:55, 29 August 2022
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−	: ~~''Main page: <a title="Welding">Welding</a>''~~Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference ~~(rules link)~~.	+	: Tubes should be cleaned before welding. Joints should have minimal gaps, otherwise welding will be difficult. Tubes must be welded around the entire circumference<ref>FSAE Rules. https://fsaeonline.com/cdsweb/gen/DocumentResources.aspx</ref>.
−

	==Analysis==		==Analysis==