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

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, while optimizing the weight

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. 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 → in

6. 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 → in

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

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

9. Suspension Assembled View
Completed Work
Suspension Assembled View

10. Completed Work
Frame and Suspension Assembly

11. Completed Work
Front Steering Rear Toe Adjustment

12. 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

13. 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 → in
Stresses:
Alternating Stress → 39.5 ksi
Midrange Stress → 20 ksi

14. 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

15. 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

16. Gantt Chart

17. 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 $
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

18. Questions?