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Table Of Contents

List of Figures
List of Tables
Design Goals
Table 1: Design Parameter Table
Thermal Processing
Figure 1: Endurance Limit vs. Hardness (Krauss 1990)
Figure 2: Steel Chemical Compositions
Stress Analysis
Load Scenario Determination
Figure 4: Fatigue Cycles vs. Imposed Average Stress (Smith 1984)
Table 2: Stress Limit Correction Factors
Input Load Determination
Table 3: Front Jump Landing Scenario
Table 5: 3G Front Cornering Load
Table 6: 3G Rear Cornering Load
Finite Element Analysis
Figure 6: FEA Constraint and Loading Methods
Table 7: Chassis FEA Results
Chassis Optimization
Tube Size Selection
Figure 7: Tube Size Distribution
Strengthening Mechanisms
Flared Holes
Stressed Body Panels
Figure 10: Test Frames
Figure 11: Test Frame Analysis
Table 8: Friction Coefficients
Figure 12: Normalized Stiffness Coefficients Vs. Sample #
Body Panel Selection
Figure 13: CES Graph of Impact Strength vs. Density
Chassis Fabrication
Frame Table and Coordinate system
Front Suspension
Preliminary Design Parameters
Table 10: Preliminary Design Envelope
Table 11: Front Kinematic Performance Goals
Component Design
Figure 14: Front Suspension Model
Figure 16: Castor (left) and Kingpin Inclination
Figure 17: Scrub Radius Diagram
Figure 18: Castor Trail Diagram
Figure 19: Aluminum Designs
Figure 20: Sheet Metal Final Design
Figure 21: X Direction Loading Case
Figure 22: Y Direction Loading Case
Figure 23: Z Direction Loading Case
Figure 24: Moment About Y Axis
Figure 25: Moment About Z Axis
Figure 26: Sheet Model Bent and Unfolded
Control Arms
Figure 28: Front Suspension at Full Compression
Figure 29: Front Suspension at Full Droop
Front Hub
Figure 30: Hub Model
Figure 31: FE Model of Hub
Rear Suspension Design and Analysis
Figure 32: Rear Suspension Assembly
Figure 33: Rear Suspension Front View
Figure 34: Planar Geometry
Figure 35: Rear Upper Control Arm
Figure 37: Stressed Axle Model
Figure 38: Carbon Fiber Axle FEA
Figure 39: Rear Knuckle Model
Figure 40: Rear Spindle Model
Figure 41: Universal Joint Model
Figure 42: Rear Spindle FEA
Figure 43: Rear Hub Model
Rear Suspension Manufacturing
Wheel Design and Analysis
Moment of Inertia
Table 13 - Carlisle Badlands
Table 14 - Carlisle at489 at23x7-10
Wheel Acceleration
Figure 46 - Wheel Acceleration vs. Applied Torque
Figure 47: Wheel Blank Model
Figure 48: Final Wheel Design
Figure 50: Torque Loading
Figure 52: Selected Motocross Tires
Wheel Fabrication
Figure 53: Machine Tools Used
Figure 54: Wheel Machining
Driver Controls
Figure 55 - Steering Rack Attachment
Figure 56 – Connecters
Steering Wheel
Table 16: Braking Force
Brake Plate design
Figure 57: Brake Assembly
Figure 58: Brake Plate
Thermal Analysis of the Rear Disc
Figure 59 - Diagram of Heating Analysis
Table 17 – Critical Parameters for Equations
Drive Train
Maximum Power
Drive Train Selection
Table 20: Rolling Resistance Test Results
Figure 66: Release Mechanism
Air Resistance
Table 21 - Velocity vs. Drag Force
Table 22: Velocity vs. Horsepower
Figure 70: Thrust of Engine vs. Aerodynamic Drag
Figure 71: Power at the Wheels After Aero Drag
Drive Train Design
Sprocket Design
Figure 72: Sprocket Dimensions
Figure 73: Secondary Sprocket FEA
Figure 74: Final Sprocket FEA
Intermediate Shafts
Figure 75: FEA of CVT Jackshaft
Final Shaft
Gear Frame Parameters
Figure 78: Chain Path Diagram
Figure 79: First Design Iterations
Figure 82: Final Design Iteration
Figure 83: Gear Frame Dimensions
Figure 84: Machined Ear Bolted to Frame
Figure 85: Gear Frame Post-Welding/ Pre-Machining
Figure 86: Final Gear Frame after Final Machining
Bearing Housing
Figure 87: Bearing Housing
Appendix A: Thermal Processing
Appendix B: Input Load Determination
Figure 92: Fox Float 2.0 Compression Force vs. Velocity
Appendix C: FEA Results
Appendix D: Stressed Panel Analysis
Appendix E: Drive Train Calculations
Appendix F: Camber Vs. Steering Angle
Appendix G: Brake Calculations
Appendix H: Chain and Sprocket Calculations
Appendix I: Brake Disc Thermal Analysis
Works Cited
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Published by Chendil Velan

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Published by: Chendil Velan on Aug 05, 2012
Copyright:Attribution Non-commercial


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