SAE Baja Senior Design Project Group Members Damon Bender, Geoffrey Hill, Christopher Maher, Alex Rodriguez, John Ross Update as of 03/30/2016

Overview Society of Automotive Engineers(SAE) hosts annual Baja style competition Rules prohibit reusing parts/designs from previous years The purpose of this project was to develop original designs for three main components of the SAE Baja vehicle to be produced and used in competition.

Competition Events Maneuverability Endurance Sled Pull Hill Climb Acceleration

Completed Work Frame Initial Design & Analysis Followed Strict SAE Rules Varying Tube Dimensions for Lightest Weight Modeled & Analyzed in NASTRAN/PATRAN Determine Deflections & Stresses Due to 4G Frontal Impact Determine Deflections & Stresses Due to 2G Roll Over Current Design & Analysis Modeled in Inventor Finalize Modifications Re-Perform Stress Analysis With Modifications

Completed Work Suspension Assembly Designed Parts Modeling & Analysis Compact/Lightweight Greatly Maneuverable Long Range of Travel Fully Adjustable Interchangeable Parts at All Corners Parts A-Arms Adjustable Rods Coil Overs, Ball Joints & Bushings Selected Spindle Modeling & Analysis Inventor

Suspension Assembled View Completed Work Suspension Assembled View

Completed Work Frame and Suspension Assembly

Completed Work Front Steering Rear Toe Adjustment

PATRAN 3D Model of Suspension Assembly Completed Work PATRAN 3D Model of Suspension Assembly

PATRAN Deflection Analysis of Suspension Assembly Completed Work PATRAN Deflection Analysis of Suspension Assembly

Completed Work Drivetrain Designed Analyzed Modeled Gear Reduction from 10 HP Engine Shafts and Keys Chain and Sprocket Selection Analyzed Force Analysis due to Torque and Loading Theoretical Deflection Modeled Inventor

Wheels & Tires Old Tire New Tire Dimensions: 25” x 8"-12” Max Speed: 41.5- 41.8 mph Weight: 15.20 lbs Load/Ply Rating: 3* New Tire Dimensions: 23"x7"-10” Max Speed: 38.0-38.5 mph Weight: 12.40 lbs Load/Ply Rating: 2*- Max Load @ 35 psi = 240 lbs

Wheels & Tires Old Wheel New Wheel Dimension: 12"x8 Material: T6061 Aluminum Alloy Weight: 7.10 lbs New Wheel Dimension: 10"x7” Material: Heat Treated T6061 Aluminum Alloy Weight: 4.75 lbs OPTIMIZED WEIGHT DIFFERENCE: 20.6 lbs

Gantt Chart

Future Work Select Appropriate Coil over Produce Plans for Frame Fabrication Maintain Involvement in Building Process Frame Design Completion is Projected for the End of This Week (March 4th, 2016) Baja Club Inherits Designs for Work to Begin Spring Break

Questions?