SAE Baja Senior Design Project Group Members Damon Bender, Geoffrey Hill, Christopher Maher, Alex Rodriguez, John Ross Update as of 04/19/2016

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, while optimizing the weight

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

Frame Analysis Final Results In PATRAN 4G Frontal Impact Stress → 10 ksi 2G Roll Over Impact Stress → 17.1 ksi 4G Frontal Impact Deflection → 2.55 in 2G Roll Over Impact Deflection → 0.143 in

Completed Work Suspension Assembly Designed Parts Analysis Compact/Lightweight Greatly Maneuverable Long Range of Travel Fully Adjustable Interchangeable Parts at All Corners Parts A-Arms Adjustable Rods FOX Float 3 Shocks, Ball Joints & Bushings Selected Spindle Analysis 2G Landing Stress → 165 𝑘𝑠𝑖 2G Landing Displacement → 0.011 in

PATRAN Maximum Stress Analysis of Suspension Assembly Completed Work PATRAN Maximum Stress Analysis of Suspension Assembly

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

Suspension Assembled View Completed Work Suspension Assembled View

Completed Work Frame and Suspension Assembly

Completed Work Front Steering Rear Toe Adjustment

Drivetrain Gears Designed Modeled In Inventor Material Supplied Power from 10 HP Engine 2 Stage Gear Reduction 2-10 tooth gears, 2-26 tooth gears Gear Ratio → 6.76:1 Modeled In Inventor Material Grade 1 Carburized Steel Grade 3 Carburized Steel Analyzed In MATLAB Lowest Bending Factor of Safety: 26 Tooth on Intermediate Shaft → 5.26 Actual Factor of Safety: (contact stresses) 10 Tooth Gear Input Shaft → 1.72 26 Tooth Gear Intermediate Shaft → 1.81

Drivetrain Shafts Designed Modeled In Inventor Supplied Power from 10 HP Engine Shafts and Keys Modeled In Inventor Analyzed In PATRAN & MATLAB Force Analysis due to Torque and Loading: Bearing Force → 8400 lbs Point of Failure Keyway → S.F. = 1.14 Key Length → 0.75 in (Brass) PATRAN Deflection → 0.002 in Stresses: Alternating Stress → 39.5 ksi Midrange Stress → 20 ksi

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

SUSPENSION OPTIMIZATION DRIVETRAIN OPTIMIZATION Optimized Vehicle Cost to Weight Comparison: FRAME OPTIMIZATION Weight (lbs) Cost Original 98 $402 Optimized 65 $897.13 Difference (%) 33% reduction 223% increase SUSPENSION OPTIMIZATION Weight (lbs) Cost Original - Optimized 94 $2403.00 Difference (%) DRIVETRAIN OPTIMIZATION Weight (lbs) Cost F.o.S Original 10 $173 1.24 Optimized 11 $196 2.34 Difference (%) 9% increase 11.7 % increase 257% increase

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