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Design & Analysis

2008

Development

DriveTrain

Chassis

DriveTrainShielding

SingleWheelVerticalImpact

SteeringandBraking

SAEtechnicalpaper2006013626

StaticEvents:300ptstotal

KennethMandeville TeamLeader

DesignReport=50to100pts

GuillermoBarba
MalloryBerry
PaulBunkers
BrianHunter
JorgeMejia
DanMoline
CharlesPhelps
JeremySchenker
JesseSoto
MattWalter
CraigWilkinson

Design=100to125pts
CostReport=15pts

BendTubes
TubeBender

CutTubes
ChopSaw

CopeTubes

Prototype=85pts

TubeNotcher

WeldTubes

Presentation=50pts

Tig &Mig Process


E70S6FillerMaterial(UTS89,000PSI)

ManufacturingTechniques

Competitions

Rackandpinionsteeringsystem
6:4:1steeringratio

DynamicEvents:700ptstotal

Discbrakes
7inchStainlesssteelcrossdrilledrotors

ManufacturingTechniques

Competitions

TheTeam

Comet780CVT
Durabletransmission
Reachtopspeedof35mph
Withstand14ftlbtorquefromengine
Use4130chromolyangleironmounts

Backboneofthecar
Endureasinglewheelverticalimpactwith
afactorofsafetyof1.5
Keepdriveraliveduringa7.9gimpact
Weighlessthan80pounds
Maxallowablestress:42100psi

BodyPanelsandskidplate
Createmoldforpanelandskidplateshape
Applymoldreleasesolution
Layepoxywithfiber(23layers)
Applyclearcoat
Polishandshinefinallayer

Acceleration=60to75pts

ProjectStatement

HillClimb=60to75pts
Maneuverability=60to75pts

Suspension

ChassisAnalysis
ANSYSwasusedforallFEAanalysis,ie.rollover,sideimpact,dropforce.
Figuresbelowsimulateashockforcewitha250lbdriver,tubing,and100lbengine

andtransmission.

Provide maximum traction for the vehicle over course obstacles


Withstand a lateral load of 616 lbf, a braking load of 409.5 lbf, and a
drop force of 1620 lbf
Wheel travel of 12 inches
Ground clearance of 14 inches (11 inches with sag)

TheSAEMiniBajaisanintercollegiatestudent
engineeringdesigncompetition.Theobjectof
thiscompetitionistosimulatearealworld
engineeringdesignproject.Ourteamis
competingtohaveourdesignacceptedfor
manufacturebyafictitiousfirm,duetoeaseof
manufacturing,pricing,andperformance.
(2008BajaSAECompetitionRules)

Objective
ANSYSFEAforfrontshockforceat0.2sec

ANSYSFEAforrearshockforceat0.2sec

MaximumVonMisesstressof39818psi

MaxVonMisesstressof27442psi

BodyPanelsandSkidPlate

SuspensionAnalysis

Thebodypanelsandtheskidplateprotectthe
driverfromobjectsflyingintothecockpit.
Theskidplatemustwithstanda
pointforceof650lbs.
Equivalentenergyabsorptionto1/8inchthickaluminum
FrontUpperSuspensionArmFEA

Kevlar/CarbonFiberBlend

RearUpperSuspensionArmFEA

RearLowerSuspensionArmRender

SuspensionVibrationAnalysis

Unsprungmass

Timeline

RearLowerSuspensionArmFEA

Themodeltobelowshowsdiagram
oftheminibaja.Thismodelwas
usedtosimulatethesprungand
unsprung massreactionasthe
vehicleencountersroughterrain.

Sprungmass

Applyclassroomknowledgetopractical
situations
AbidebyallSAEregulationsandbuilda
competitiveallterrainvehicle
Buildahighperforming,lowcost,anddurable
MiniBaja
Createanaestheticallyappealingvehicle
CompetewellattheSAEMiniBajacompetitions
Havefun

Task

Date

BodyPanelsinstallation

3/28/2008

FramePainting,finalwelding

4/1/2008

Dyno finished

4/1/2008

Finalcarassembly

4/4/2008

Enginebreakin

4/8/2008

Swaybardesign

4/25/2008

VehicleTesting

5/1/2008

Competition

5/20/2008

RockCrawl=60to75pts

EnduranceRace=400pts

SafetyConcerns

LessonsLearned
Workeffectivelyasateamtoaccomplishagiventask
usinggoodorganization.(i.e.workdistributedevenly
throughsubteams)
Designprocessappliedtorealworldsituations
TheimportanceofaccurateFEA,andtheabilityto
chooseanacceptablefactorofsafety
Maintainingadynamictimelineisessentialtotimely
completion
Welldefinedengineeringspecificationsaidindesign

Hazardousmaterials
Bodysuits
Respirators

Machiningsafetyconcerns
Metalshavings
Nolooseclothing
Safetygoggles,gloves

Driversafety
Rollcage
DriverRestraints
Helmet,racesuit
Fireextinguisherincockpit

Budget
Subteam

Cost

Chassis

$481.50

Suspension

$1850.37

Steeringandbraking

$643.75

DriveTrain

$2191.34

BodyPanels

$705.06

SkidPlate

$176.12

Total

$6048.14

TestPlan
Suspensionandchassis
Looserailroadtrackstests
Minibaja willbedrivenover
railroadtiestotunesuspension

Tracktests
Fillsmeres MesaParktotestthecarin
competitionsimilarareas

Speedtests
Testspeedtofindcorrectgear
ratiotohavethemaximum
amountofpowerwithamaximumspeedof30mph

Simulinkwasusedtoanalyzethe
responseofthesuspensionsystemto
findtheidealspringanddamper
constantsforthesystem(k2 andb2).
Theotherk1 andb1 areconstants
relatedtothespringanddamper
coefficientsofthetires.

Engineering and Science Student Design Showcase