The lightweight design for the frame structure of FSEC

Vehicle light-weighting is aimed at reducing the curb weight of the vehicle to ensure its strength, safety, and performance, as well as to reduce fuel consumption and exhaust emissions. The use of modern simulation technology in structural optimization design is one of the most important methods to achieve structural lightweight. In this paper, we study the size optimization of the frame structure based on the rules and requirements specified in Formula Student Eclectic China (FSEC), following the race’s rules and requirements, while satisfying the vehicle’s dynamic and static performance requirements. First, a three-dimensional geometric model of the frame structure is developed, and the static and dynamic performance of the frame is simulated using the finite element method. Next, structural size optimization is carried out under the premise of ensuring structural performance. Finally, the feasibility of the optimized structure is evaluated by comparing its performance before and after optimization. The research results show that the final frame structure has been reduced by 7.6 kg and the weight reduction has reached 22.4%. All performance indices meet the requirements of the competition, and a good lightweight effect has been achieved.