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

2. 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.

3. Competition Events Maneuverability Endurance Sled Pull Hill Climb
Acceleration

4. 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

5. 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

6. Suspension Assembled View
Completed Work
Suspension Assembled View

7. Completed Work
Frame and Suspension Assembly

8. Completed Work
Front Steering Rear Toe Adjustment

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

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

11. 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

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

13. 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

14. Gantt Chart

15. 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

16. Questions?