1.

0 INTRODUCTION

1.1 Project Background

Chassis is the most important part of fabricating of the car manufacturing. The
department plays an essential role because it is obviously related to other components of the
vehicle. The minor change in dimension and design of the chassis will affect the designation
of other components of the vehicle. Chassis consist of an internal framework that supports a
man-made object in its construction and use.

Chassis serves as an aerodynamics device, both by directing air but also by supporting
the deflection of other aero components. The chassis also act as the driver’s centre of
confidence. If the driver does not feel safe, either due to weak impact zones or flexy
suspension feedback, it will not be going fast. Arguably more importantly, he may be injured
by an unsafe chassis. Finally, the driver must be entirely comfortable.

A good chassis must have following several characteristics which are:

1. Maintain the suspension mounting locations so that handling is safe and consistent under
high cornering and bump loads.
2. Support the body panels and other passenger components so that everything feels
comfort.
3. Be structurally sound in every aspect over the expected life of the car.
4. Protect the driver from a possibility of external injurie and harm.

1.2 Scope of Work

There are several structural requirements that need to be followed in fabrications of chassis
which are:

 The chassis frame must be made from structural steel or structural steel alloy tubing
meeting the ASTM classification or ISO 4948 designations. Alloy steel having at least
one alloy element the mass content which >5% are forbidden.
 A tube/ roll shape design is the best optional for the team to use as a frame of chassis
 The uses of material for tube frame and panel must be capable of withstanding a static
load of higher than 700N (approximately 70kg)
 Upper back must be designed specifically for easier to disassemble for battery changing
purpose and air compressor maintenance
 Driver visibility: the driver must have adequate visibility to the front and sides of the car.
With the driver seated in a normal driving position, they must have a field vision of 200
degrees as a minimum or minimum 100 degrees to both side of the driver. The required
visibility may be obtained by the driver when turning head or use the mirrors.
 The structural of chassis are preferable in monocoque type.

1.3 Objectives
The project design work is going to focus on the basic objectives while striving in achieving
the major aims. There are several of clear objectives that we need to obtain and achieved
which are:

1. To perform a design and analysis of the chassis car withal working components.
2. To design a chassis that will be easily adaptable and adjustable.
3. To produce a major compartment in a car project with an excellent functional utility.
4. To ensure that the project comply to the safety standards that has been determined.
5. To improve the usable of CAD software such as CATIA and Solidworks.
6. To organize a suitable material and design that can be used for recreational.

1.4 Design Process

The design process is an approach for breaking don a large project into manageable
chunks. This aspect is important as to define the steps needed to tackle each project, and to
hold to all the idea and sketches throughout the process. There are seven steps that can be
used for this project as it helps the students to minimize the defect that can be redesigned
properly and controllable.
 Figure 1: Design process chart

2.0 DESIGN REVIEW

2.1 Design Background

Figure 2: Views of the chassis

From the figure above, all the modification in design 1 has been done. However,
before the final modification made, there are many subpart of the car where the dimension
does not fit to other parts, which are front bodywork, rear bodywork, floor panel, rooftop,
back panel, and rear floor panel.as the previous dimension thickness of panel are at 10
millimetres, it is modified into 2 millimetres due to many aspects related. On the front roll
bar, the thickness and dimension need to be decrease in t to provide space.
2.2 Product Modification
We have made some improvement for front and rear lower bodywork to fit with the
different dimension related to other part involved. For modification involve at the front
bodywork, it is modified by adding side panel to reduce time and cost compare to separated
manufacturing, besides it is for safety purpose. Moreover, the modification made by reduce
the dimension of bodywork into compact size purposely to reduce unnecessary space in our
car project.

Figure 3: Front bodywork modification

Meanwhile for rear lower bodywork, it is modified into the simplest design suitable
for manufacturing process and attached perfectly with the cover at the side of our car project.
Furthermore, by adding panel is purposely to protect the engine and other component to
provide complete full set. The lower back also designed specifically that it can be
disassemble in order to do maintenance or inspection for engine. Also, the back-body design
has air flow to prevent engine from overheating.

Figure 4: Rear lower bodywork modification

Figure 5: Modification of air flow to prevent engine from overheating.

2.3 Engineering Analysis

 Engineering analysis is essential aspect that needs to be involve in every project
especially when it is related with the automotive project. Engineering analysis involves the
application of scientific analytic principles and processes to reveal the properties and state of
a system, device or mechanism under study. It is indispensable analysis tool to analyse the
processes, integration, and yield effectively in order to enhance the competitiveness of a
project conducted. Figure below shows the engineering analysis of Von Mises Stress and
translational displacement.

Figure 6: Von Mises Stress analysis

Figure 7: Translational displacement analysis

σ ultimate
Factor of Safety =
σ actual

250 ×106
Factor of Safety = =4.6
54.3 ×106

 By using maximum stress applied on the chassis, the factor of safety for chassis is 4.6.
2.4 Drawing

Figure 8: Bill of Materials for Chassis

Figure 9: Chassis Frame

 Figure 10: Front bodywork drawing

Figure 11: Rear Lower bodywork drawing

 Figure 12: Rear top bodywork drawing

3.0 PROJECT MANAGEMENT

3.1 Project Planning

Gantt Chart (October 2020 - January 2020)

1 3 5 7 9 11 13 15
Design and drawing revision
Assembly & Final design specification
Software decision
Work distribution
Fabricating preparation
Department Tasks

Manufacturing operation
Assembly operation
Assembly simulation
Operating simulation
Final animation simulation
Full testing
Operation & manufacturing cost calculation
Presentation & report writing
Report submission
Logbook and minute of meeting

Week

Start Week to complete

Figure 13: Gantt chart

 Table 1: Job planning specifications
No Tasks Start (Week) Completion
. (week)
1. Design & drawing part revision 1 1
2. Assembly & final design specification 1 2
3. Software decision 2 1
4. Work distribution 2 2
5. Fabricating operation 4 3
6. Manufacturing operation 5 3
7. Assembly operation 7 2
8. Assembly operation 9 3
9. Operating simulation 10 1
10. Final animation simulation 11 2
11. Full testing 12 1
12. Operation & manufacturing cost calculation 13 2
13. Presentation & report writing 14 1
14. Report submission 14 1
15. Logbook & minute of meeting 1 14

3.2 Organization and Job Scope

The chassis department comprises of 6 team members and each of them are assigned
with a specific job based on their position and responsibilities. The figure and table below
shows the organizational chart and job scope respectively.

Figure 14: Organizational chart of Chassis department

 Table 2: Job Scope
Members Job Description

Head of Department  Ensure all the progresses in the department run

Faiz Aiman bin Badrulhisham smoothly by following the Gantt chart.
 Divide job scope to the committee to ensure the
project run smoothly within time.
 Monitoring and keep receiving the updated
information about the latest data on car project

 Giving ideas and analysing the best suitable

Senior Engineer material of the chassis making.
Sarif Syahir bin Sarif Salleh  Ensure the designed chassis meet the customer’s
requirement.
 Ensure the quality and safety of the designed
chassis.
 Solving the problem involving defect or
engineering analysis

Design Engineer  Design the chassis / other components related to

Muhammad Hafiz bin Aziz the chassis.
 Ensure that the final design meets the dimension
and fit in the assembly system

Senior Technician  As a manpower to fabricate the chassis based on

Muhammad Hafiy bin Mohd Fadzil designed specifications.

Quality Surveyor  Ensure that the cost and the materials needed to
Raja Muhammad Amiril Isyraq bin fabricate the chassis are in budget and stock up
Raja Azmy based on requirement.
3.3 Individual Job Work

Due to the COVID-19 Corona Virus outbreak, students were unable to execute any
fabrications that should be done in the workshop. The decision to digitized the fabrication
process by converting hands on process to simulation and animation disrupted the plans from
the first phase. Most of meetings and discussion are done online during the Movement
Control Order (MCO) since it is compulsory for all citizens to stay home. The simulation and
animation process are done by using CATIA and Solidworks.

The job scope for the second phase were no different from the first phase regardless
of the outbreak. The HOD, Faiz Aiman decided to divide the department into 3 groups. The
design team which consist of the same pair which are Muhammad Hafiz and himself are still
responsible for the design, simulation and animation of the product. Sarif Syahir and
Muhammad Hafiy are in charge of any video editing, content editing as well as creating
slides for presentation. Next, Raja Muhammad with the help of other members are
responsible for gathering information from the first phase of the project and documentation of
the project. HOD always monitor and keep on receiving updates from the team.

Design team maintained the blueprint while working hard on the animation of the
fabricating process. Since animation work is foreign to the design team, there is always a
room to learn and apply the knowledge. Sarif Syahir and Muhammad Hafiy work hard for the
video editing especially during presentation. The editing of the videos is translated as good
quality video rendering and combining videos. Overall, the digitalization of the project
fabrication gave us new experience in handling our task online. Moreover, this experience
student a taste of Industrial 4.0 as the industries are setting foot in.
4.0 COSTING AND MARKETING

4.1 Material Selection

Before the early discussion were conducted, there are several chosen materials that
have been listed as an option which meet most of the requirement needed to build the chassis.
The material selection must be considered with the essential aspects such as the cost,
strength, machinability and material properties. The chosen of the material would be divided
into 2 sections which are body work and chassis frame.

Figure 15: Complete chassis body work

For chassis bodywork, the suitable criteria that we need the most are it must be high
durability for easier machining, lightweight to reduce the weight percent of the whole-body
car and lastly is the material must be high resist the corrosion to ensure the long lifetime of
the car. By that characteristics, there are two possible material that nearly meet the
requirement above which are aluminium and carbon fibre. These two materials are worldwide
and dominantly being used in automotive part production.

However, this range price for our project is economical and can be afford by any
community people. Hence, we had chose aluminium as the best selection due to the cost and
production time. The other reason we choose this material is because it is easy to recycle by
melting it and reuse it again for other purpose. Next, aluminum is more sustain compare to
carbon fiber. Lastly our chosen material is environmentally safe.
 Figure 16: Complete chassis frame

Meanwhile for frame, the preferable material is mild steel ASTM-36 in form of tube
shape. This is because this material are widely used in manufacture process due to easy to
weld that is suitable to grinding, punching drilling and machining process. Besides, this type
of material is easy to bend thus it is suitable for our frame design.

4.2 Market cost

Regarding on United State of America market, the current price based on business
insider market for 1kg of aluminum will take costs about 2.06 USD which is equivalent to
RM8.32 whereas carbon fiber is RM83.2/kg. That means the price of carbon fiber is 10 times
more expensive compare to aluminum. Usually the carbon fiber is regularly used in small
dimension production such as bicycles. Hence, it is not suitable to used in our project car as
the total weight of bodywork reach up until 72kg. Throughout into the conclusion
mathematically, the total price of aluminum material only takes RM599.04, but for carbon
fiber the price would go up until RM5999.04.

For chassis frame, the price range per kg is at range of between USD 2.30 until
USD2.60, thus making it around RM10.51 per kilograms. This material is used totally in the
frame design that the weight about 75kg. Hence, based on calculation, the total cost will be
about RM788.25. As a conclusion, the total price of both materials chosen for frame and
bodywork would take a cost at RM1387.29. the price range is reasonable and affordable as
the price range would be at between RM6000 to RM7000. Hence, the chassis cost is
accepted.
5.0 CONCLUSION
Based on the progression that have been made during fabricating the chassis, there are
several limitations occur in developing the chassis frame. Basically, we are using CATIA
software as a medium to represent and interpret the data and analysis due to the pandemic
that hit around world. Sometimes, we are having a trouble during the assembly and designing
the dimension because it is hard to communicate and work together under one roof. Besides
that, the lack of workshop practice and no physical fabrication make it harder to develop the
knowledge skill in building the chassis.