faculty advisor abdelmageed elmustafa group members: john merritt frances othersen christopher davis...
TRANSCRIPT
•Faculty Advisor• Abdelmageed Elmustafa
•GROUP MEMBERS:•JOHN MERRITT
•FRANCES OTHERSEN•CHRISTOPHER DAVIS
•JAMES CHAPMAN•JOSEPH FANNING
Baja SAE
Objective
● Purpose: Design and build an off road vehicle to meet the specifications of the SAE Baja competition.● Tasks: A. Redesign a rear suspension design that uses traditional
trailing links that can later incorporate passive rear steer.
B. Design a two speed gearbox using spur gears.
● Total Budget: $12,000● Projected Completion date: April 30, 2015● Goal: Place in the top ½ of competitors overall.
Work Breakdown
● Gearbox Members:
○ John Merritt
• Overall team leader
• Lead Design
○ Frances Othersen• Analytical testing• Scribe
○ James ChapmanDesign/Material Selection
●Suspension Members:
○ Chris Davis• Analytical Testing• Scribe
○ Joseph Fanning• Lead design
Gantt Chart
Analysis was performed for frame
using three different loadings:
1. Frontal impact with another car or
part of course (3000 lbs)
2. Frontal rollover, roof takes force
(2400 lbs)
3. Side Impact / Rollover (2000 lbs)
Maximum Stress Observed: 64.2 ksi
Maximum Deflection Observed: 1.78
inches
Frame Analysis
Two Speed Gearbox
Initial Conditions for Calculations:
• 9.6 delivered horsepower
• 14 ft-lbf torque
• 987 rpm input speed, 115 rpm
output speed
• Moderate shock levels,
occasionally high
• Maximum gearbox size allowed:
18.07 in x 4.55 in x 12 in
Two Speed Gearbox
Calculated Results
Torque Ranges: 51 ft-lbf to 442 ft-lbf
Velocity Ranges: 350 ft/min to 540
ft/min
Transmitted Load Ranges: 590 lbf to
880 lbf
Safety Factor: n = 1.4
Gear Ratios:
8.66:1 and 11.2:1
Gearbox Analytical Test
Gear 5:Maximum Stress Observed: 1094 psiMaximum Deflection Observed: 2.209e-005 in
Gear 6:Maximum Stress Observed: 775 psiMaximum Deflection Observed: 3.354e-005 in
Yield Stress: 89984.6 psiTensile Strength: 104982 psi
Initial Suspension Design
Initial rear-steer design pivots around z-
axis, allowing it tow in/out of 1° to 3°
degrees based on travel.
Advantages
• Can be built to vehicle specifics
• Can use any size bushing (Knuckle is
designed based on bushing)
• Increased maneuverability
Disadvantages
• Cost (Materials, machining)
• Not easy to fix/repair/adjust
Rear Suspension Traditional Trailing Arm
Traditional trailing arm design
is similar to the passive rear
steer, however does not pivot
around z-axis.
Advantages:
• Able to utilize many different hub
assemblies
• Easy to repair/adjust
• Cheaper (Materials, machining)
Disadvantages:
• Does not allow wheels to tow in/out
• Less maneuverability
Rear Swing Arm Analysis
Analytical Test SolidWorksAnalytical Test SolidWorks
Patran:Maximum stress observed: 1530 psiMaximum deformation observed: 6.94e-001 in
SolidWorks:Maximum stress observed: 518 psiMaximum deformation observed: 2.54e-003 in
Deformation and stress analysis without shock absorbers
Future Work
• Assembly
• Test Driving
• Performance Tuning
• Final Adjustments
Any Questions?