Development of Lightweight Chassis and Efficient Drivetrain for Formula Student Applications

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This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.

Year : 2025 | Volume : 12 | 03 | Page :
    By

    Aamir chaudhary,

  • Manan Garg,

  • Nitin Pandey,

  • Sarthak Sikka,

  • Sushant Bharadwaj,

  • Rakesh Chander Saini,

  1. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  2. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  3. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  4. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  5. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  6. Assistant Professor, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India

Abstract

The chassis and drivetrain of a Formula Student vehicle are designed, analyzed, and optimized in this research study with an emphasis on manufacturability, performance, and safety. The project emphasizes the use of advanced engineering toolssuch as SolidWorksfor computer-aided design (CAD) and ANSYS for structural analysis to evaluate the chassis under various dynamic conditions. The primary objective is to ensure that the driver remains safe inside the cockpit while maintaining a lightweight, rigid, and ergonomically efficient structure that can house all necessary components.The study is divided into two major objectives. The first involves designing, manufacturing, and testing the Formula SAE race car chassis by considering critical factors such as vehicle dynamics, torsional rigidity, component packaging, ergonomics, and overall driver safety. Special focus is given to optimizing the chassis for structural strength while minimizing unnecessary weight. The second objective emphasizes the design and optimization of the drivetrain, including chain, sprockets, axles, and differential systems, to achieve maximum efficiency and smooth power transmission. References from SAE research papers and standard textbooks were extensively utilized to validate calculations and improve design accuracy The CAD models were developed in SolidWorks 2020–21, followed by 2D and 3D structural simulations in ANSYS 2021 to evaluate the chassis against frontal, side, and torsional loads. Fabrication was carried out in-house using TIG and arc welding, supported by jigs and fixtures to ensure accuracy. The high strength-to-weight ratio, weldability, and availability of AISI 4130 chromium-molybdenum alloy steel made it the material of choice for the chassis.The final outcomes demonstrate that the optimized chassis and drivetrain not only meet competition rulebook standards but also enhance driver safety, performance reliability, and structural durability. These results serve as a valuable contribution to the ongoing development of cost-effective and efficient Formula Student vehicles.

Keywords: Chassis design, drivetrain optimization, structural analysis, AISI 4130 steel, formula student vehicle

How to cite this article:
Aamir chaudhary, Manan Garg, Nitin Pandey, Sarthak Sikka, Sushant Bharadwaj, Rakesh Chander Saini. Development of Lightweight Chassis and Efficient Drivetrain for Formula Student Applications. Journal of Automobile Engineering and Applications. 2025; 12(03):-.
How to cite this URL:
Aamir chaudhary, Manan Garg, Nitin Pandey, Sarthak Sikka, Sushant Bharadwaj, Rakesh Chander Saini. Development of Lightweight Chassis and Efficient Drivetrain for Formula Student Applications. Journal of Automobile Engineering and Applications. 2025; 12(03):-. Available from: https://journals.stmjournals.com/joaea/article=2025/view=227984


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Ahead of Print Subscription Original Research
Volume 12
03
Received 07/08/2025
Accepted 04/09/2025
Published 16/09/2025
Publication Time 40 Days
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