Design Review #2

Statement of Work
Baja SAE is an international engineering

design competition. Student teams design, build, and test a single seat, four-wheel off-

road vehicle. We will compete in the Baja SAE Carolina competition in April 2010.

Team Responsibilities
Sam Moran Team Captain; Frame; Welder/Fabricator
Michael Guilfoy Treasurer; Steering; Machinist/Fabricator Sam Weitkemper Powertrain; Secretary Dan Pickering Suspension; Machinist/Fabricator Matt Wantland Analyst; Materials Acquisition; Fabricator Ben McNealy Brakes; Dynamic Analysis Ahmed Al-Gattan Safety

Project Background: Baja SAE

Baja SAE Carolina will be held

April 8th-11th, 2010, in Greenville, South Carolina 106 teams registered Dynamic Testing Events: Acceleration Suspension Traction/Pulling Maneuverability 4-hour Endurance Race Static Events: Design Presentation/Report Prototype Cost

Project Background: Baja SAE

Why is this project important?
Real-world engineering design project

Concept Selection Design decisions based on pre-determined competition

specifications and safety concerns

Three-Dimensional Modeling Limiting Factor 10 horsepower Briggs & Stratton Engine

Fabrication Experience

Welding Machining

Vehicle Engineering Specifications

Overall Vehicle Dimensions Specification Ground Clearance Track Width Wheelbase Weight Material 10" 55" 60" < 500 lbs. Frame Steel, Sy = 52.9 ksi Baja SAE Sy = 52.9 ksi Specified by Team Team Team Advisors Designed 10" 55" 60" ~500 lbs.

Size A
Size B Length Width Height Weight

1.25" 1018 steel

1.00" 1018 steel 80 35 52 < 100 lbs.

Baja SAE
Baja SAE Team Team Team Team

32.0 feet
65.5 feet 81.5 30.25 51.8 67.8 lbs.

Vehicle Engineering Specifications

Powertrain

Specification Target
Max Ratio Min Ratio Top Speed 35.60 6.98 35 MPH

Designed
39.75 5.7 34 MPH

Max Gradient
Max Engine Power Max Engine Torque Idle

70%
9.1 HP 13.8 ft-lbs. 1750 RPM

52%
9.1 HP 13.8 ft-lbs. 1750 RPM

Max RPM
Weight Tire Diameter

3800 RPM
< 150 lbs. 22 inches

3800 RPM
120 lbs. 22 inches

Vehicle Engineering Specifications

Suspension Specification Suspension Travel Spring Rates Camber Bump Steer Weight 10 Front: 105 lb/in Rear: 145 lb/in Front: 5.0 Rear: 0.0 0.0 < 65 lbs. Specified by Team Suspension Synthesis Team Team Team Specified by Team/Advisors Team ----Designed 10 Front: 120 lb/in Rear: 140 lb/in Front: 5.0 Rear: 0.0 0.0 ~50 lbs. Designed 10.02 feet 4.75 inches 1.5 turns

Steering
Specification Turning Radius Rack & Pinion Travel Lock-to-Lock 10 feet 4.25 inches 1.5 turns

Ackerman Angle

39.75

Team

39.55

Final Vehicle Concept

Frame Bends

Frame

Drivetrain Design - Transmission

CVTech CVT mated to a Dana H-12 transaxle

Pros: Simple, proven reliability, F/N/R, auto-locking

differential Cons: Heavy

Drivetrain Design Axle

Drivetrain Stress Analysis

Conservative analysis: Max axle torque = Max motor torque * max gear ratio = (14.5 ft-

lbs) * (39.75) = 580 ft-lbs

Shear stress = T*C/J * Kt= (580 ft-lbs) * (0.362) ft / 0.0270 ft^4 *

1.78 = 138 ksi

Shear strength (4340 @ HRC 52) 0.577 * (260 ksi) = 150 ksi Factor of Safety = 150 / 138 = 1.1 Fatigue life (calculated using FatigueCalculator tool) > 1500

cycles

Drivetrain Stress Analysis

Using same CV joints that worked well in the 2009

competition

Axle assemblies are rated by manufacturer to 700 ft-lbs

(includes a factor of safety), and that vehicle uses an engine that produces twice as much power and would increase part cost

Using hollow axles would at best save 0.5 lbs per axle In our case, conservative analysis did not add to cost

Drivetrain Design - Axle

4340 Q&T steel

Splined ends to fit CV joints

Suspension System
Suspension Analysis Overview
Travel: Jounce: Rebound: Ground Clearance: Roll Center: Travel: Jounce: Rebound: Ground Clearance: Roll Center: Front Suspension: Camber 10 in 5.5 Change: 8 in Jounce: 4.3 2 in Rebound: 1.2 10 in above the ground 3.05 in Rear Suspension: Camber 8 in 0 Change: 6 in Jounce: 0 2 in Rebound: 0 10 in At the ground degrees degrees degrees

degrees degrees degrees

Suspension System
Shock and Spring Analysis: Loading: 4 g's lb/in Loading: 5 g's lb/in Front Shocks: Rear Shocks: Travel Travel 20.27514.55 20.0016.215 18.0012.00 From Synthesis: 5.73" Stroke 3.79" Stroke Polaris Website lb/in Travel Front Shocks: 6" Stroke Spring 120 lb/in Spring 105 lb/in Spring 145 lb/in Spring Constant 105.3719 Front: Spring Constant 142.3406 Rear: Force in Spring Front: Force in Spring Front: 903 lb/in Spring Constant 131.7149 Front: Spring Constant 177.9258 Rear: Force in Spring 1129 Front: Force in Spring 1040 Front:

lbs

lbs

Shock - Fox Podium X Spring - 120#/IN, 10.5", Red 18.01 (Extended Length) x 6.00 (Stroke) 18.0012.00

832

lbs

lbs

Travel Rear Shocks:

6" Stroke

Spring 140 lb/in

Shock - Fox Podium X Spring - 140#/IN, 10.5", Red

18.01 (Extended Length) x 6.00 (Stroke)

Suspension System
Front Suspension View

Suspension System
Rear Suspension View

Suspension Stress Analysis

A-Arm Material Specifications Tubing Size Diameter (in) Wall (in) c (in) I moment (in4) 1 Inch 1 0.075 0.5 0.02346 1.25 Inch 1.25 0.075 0.625 0.04797

Fmax Bending (lbs)

A-Arm tube Length
Tubing Yield Strength

156.5
15.875 in
53 Ksi

256.0

Suspension Stress Analysis

Mounting Bracket Stress Analysis: y = Loading: Weight of Car: Dynamic Loading (P): P = A P A= t= 2 680 1360 A= A= t= 0.034 53700 psi Shear and Compression: g's t= 0.0625 lbs 1/16 lbs = 29013.33 2wt 0.75t P 0.75 in in in psi F.S. = t= = y F.S. = 1/8 in 3.70 0.125 in 1/8 in 14506.67 psi

F.S. = t=

1.85

Steering System
Major Goal turning radius less than 10 feet

Procured rack and pinion drive had greater travel than specified by vendor 4.75 inches rather than 4.25 inches of travel 1.5 turns lock-to-lock Allows for a greater steering angles Allows for shorter turning radius
Outside Wheel Steering Angle Inside Wheel Steering Angle 37.5 41.6 degrees degrees

Ackerman Steering Angle

Turning Radius

39.55
10.02

degrees
feet

Braking system
Components:

Dual US Brake master cylinders, 7/8 bore

Wilwood reverse mount pedal Polaris Outlaw front rotors and calipers Polaris Ranger rear rotors and calipers

AN-3 flex steel brake lines

Polaris 10mm pressure switch Polaris brake light

Weight Distribution Analysis

Design Specifications:
55% rear weight bias Center of Mass as low as possible to ground level

Design Results:
54.3% rear weight bias

Center of Mass = 25.3 in above ground level

Rollover Potential Analysis

Dynamic Rollover Threshold
30

Maximum Safe Velocity (mph)

25

20

15

10

0 0 5 10 15 20 25 30 35 40 45 50

Turning Radius (ft)

Dynamic analysis based on COM height, roll center, and spring rate Vehicle will be rollover-resistant when cornering at reasonable speeds

Torque Analysis
Torque vs. Incline
1600

1400

Resistive Torque (lb-ft)

1200 1000 800 600 400 200 0 0 5 10 15 20 25 30 35

Percent Grade

Based on front/rear weight distribution and torque at wheels Result: Front wheels will stay on the ground under foreseeable

circumstances

Vehicle Safety Considerations

Engine Spill Shield made of HDPE
CVT Cover eliminate hand access, made of HDPE Kill Switches 2 required, cockpit and external

Transponder MYLaps rechargeable power

Safety Harness 5 strap system, 3 lap belt, quick release

connecters
Fire Extinguisher 5 BC rating, dial pressure gauge
Tube Padding standard 1.5 foam padding

Vehicle Safety Considerations

Welding Helmet new auto-darkening mask
Safety Glasses always required during fabrication Ear Plugs required for cutting/grinding metal

Helmet motor-cross style, 1-piece composite

Neck Collar SFI 3.3, full 360 coverage Arm Restraints SFI 3.3, attach to driver harness

Head Restraint SFI 42.2, foam pad

activity

week

Jan 18 DESIGN

Jan 25

Feb 1

Feb 8

Feb 15

Feb 22

Mar 1

Mar 8

Mar 15

Mar 22

Mar 29

April 5

April 12

frame suspension steering design review I braking complete design tubing tools drivetrain suspension brakes drivetrain steering safety equipment engine nuts 'n' bolts

Jan 20 Jan 25 PURCHASING PURCHASING

FABRICATION/ASSEMBLY tube bending welding fixtures fabricate frame suspension brakes drivetrain steering safety equipment design review II drivable vehicle bells and whistles paint competition prep competition-ready design review III on-road off-road competition design review IV

FABRICATION/ASSEMBLY

Feb 17 Feb 28 Mar 13

Mar 28 Mar 31 TESTING

April 8-11 April 21

activity

week

Feb 15 PURCHASING

Feb 22

Mar 1

Mar 8

Mar 15

Mar 22

Mar 29

tubing tools drivetrain suspension brakes drivetrain steering safety equipment engine nuts 'n' bolts FABRICATION/ASSEMBLY tube bending welding fixtures fabricate frame suspension brakes drivetrain steering safety equipment design review II drivable vehicle bells and whistles paint competition prep competition-ready design review III

Feb 17 Feb 28 Mar 13

Mar 28 Mar 31

Budget
Original Budgeted Retail Cost Retail Cost Customer Cost

Competition Expenses Vehicle System Costs

Frame Powertrain

3,000.00

3,100.00

2,100.00

$ $

1,100.00 3,785.00

$ $

1,100.00 6,290.34

$ $

50.00 3,033.69

Suspension
Steering Braking Tires and Maintenance Miscellaneous

$
$ $ $ $ $ $ $ $

2,178.29
345.00 1,124.09 396.00 500.00 9,428.38 1,450.00 151,350.00 165,228.38

$
$ $ $ $ $ $ $

3,600.00
269.95 1,124.09 500.00 1,750.00 14,634.38 900.00 154,950.00

$
$ $ $ $ $ $ $ $

1,648.00
269.95 653.00 200.00 1,000.00 6,854.64 900.00 9,854.64

TOTAL VEHICLE EXPENSES

Team Operation Expenses Team Labor Expenses Total Anticipated Costs

$ 173,584.38

Budget
Hourly Rate Item Engineering Description Design & Analysis Retail Rate $75.00 Customer Rate $0.00 Quantity 1300 Extended Cost Retail Cost $97,500.00 Customer Cost $0.00

Fabrication

Machining Time Welding Fixtures Tube Bending Welding Assembly

$50.00 $45.00 $45.00 $45.00 $45.00

$0.00 $0.00 $0.00 $0.00 $0.00

30 20 6 144 840

$1,500.00 $900.00 $270.00 $6,480.00 $37,800.00

$0.00 $0.00 $0.00 $0.00 $0.00

Testing

Testing & Analysis

$75.00

$0.00

140

$10,500.00

$0.00

Total Labor Costs

2480

$154,950.00

$0.00

Donations Received
Polaris Industries:

$5,647.23 in parts for $2,533.00 Suspension, brake, safety, and driveshaft components $232.00 CVT for $130.00 Tenaris Coiled Tubes 150 feet of tubing QwikService Steel 200+ feet of various tubing and steel $2,074.60 in parts for $371.69 Dana Transaxle, locking differential, and driveshaft components $1,000 towards travel costs to competition in South Carolina

CVTech-IBC:

Tubing:

Ariens:

The University of Tulsa Student Association

Tulsa Baja Racing Sponsors

Hurricane Motor Works The University of Tulsa Department of Mechanical Engineering The University of Tulsa Student Association Bendco Polaris Industries QuikService Steel Tenaris Coiled Tubes Briggs & Stratton Ariens Corp. CVTech-IBC

Original Retail Cost Vehicle System Costs Frame System Total Powertrain Transaxle Engine CVT Rear Drive Axles Miscellaneous System Total Tubing - Donated Tubing - Purchased $ $ $ $ $ $ $ $ $ 750.00 350.00 1,100.00 1,320.00 450.00 130.00 1,000.00 885.00 3,785.00

Updated Retail Customer Cost Cost $ $ $ $ $ $ $ $ $ 750.00 350.00 1,100.00 1,653.12 628.00 232.00 2,965.00 812.22 6,290.34 $ $ $ $ $ $ $ $ $ 50.00 50.00 130.00 2,503.69 400.00 3,033.69

Suspension

Shocks
A-Arms Wheel Uprights

$
$ $ $

1,160.00
250.00 768.29 2,178.29 98.00 247.00 345.00 1,124.09 396.00 500.00 9,428.38

$
$ $ $ $ $ $ $ $ $ $

1,700.00
800.00 1,100.00 3,600.00 94.95 175.00 269.95 1,500.00 500.00 1,750.00 15,010.29

$
$ $ $ $ $ $ $ $ $ $

810.00
438.00 400.00 1,648.00 94.95 175.00 269.95 653.00 200.00 1,000.00 6,854.64

System Total Steering System Total Braking Tires and Maintenance Miscellaneous TOTAL VEHICLE EXPENSES Rack and Pinion Accessories

$ $ $ $ $ $ $

Original Retail Updated Retail Customer Cost Cost Cost Competition Expenses Travel to South Carolina Hotel Transportation and More TOTAL Entry Fee TOTAL COMPETITION EXPENSES Vehicle System Costs TOTAL VEHICLE EXPENSES Team Operation Expenses Driving/Safety Gear Team Uniforms Office Supplies Fabrication Tools TOTAL OPERATION EXPENSES Team Labor Expenses Total Engineering Total Fabrication Total Testing TOTAL LABOR EXPENSES Total Anticipated Costs $ $ $ $ 97,500.00 43,350.00 10,500.00 151,350.00 $ $ $ $ 97,500.00 46,950.00 10,500.00 154,950.00 $ $ $ $ $ 9,442.95 $ $ $ $ $ 800.00 300.00 100.00 250.00 1,450.00 $ $ $ $ $ 200.00 300.00 100.00 300.00 900.00 $ $ $ $ $ 200.00 300.00 100.00 300.00 900.00 $ 9,428.38 $ 15,010.29 $ 6,442.95 $ $ $ $ $ 1,000.00 1,000.00 2,000.00 1,000.00 3,000.00 $ $ $ $ $ 1,100.00 1,000.00 2,100.00 1,000.00 3,100.00 $ $ $ $ $ 100.00 1,000.00 1,100.00 1,000.00 2,100.00

$ 165,228.38

$ 173,960.29