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 8
th
-11
th
, 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 Specified by Designed
Ground Clearance 10" Team 10"
Track Width 55" Team 55"
Wheelbase 60" Team 60"
Weight < 500 lbs. Advisors ~500 lbs.
Frame
Material Steel, S
y
= 52.9 ksi Baja SAE S
y
= 52.9 ksi
Size A 1.25" 1018 steel Baja SAE 32.0 feet
Size B 1.00" 1018 steel Baja SAE 65.5 feet
Length 80 Team 81.5
Width 35 Team 30.25
Height 52 Team 51.8
Weight < 100 lbs. Team 67.8 lbs.
Vehicle Engineering Specifications
Powertrain
Specification Target Designed
Max Ratio 35.60 39.75
Min Ratio 6.98 5.7
Top Speed 35 MPH 34 MPH
Max Gradient 70% 52%
Max Engine Power 9.1 HP 9.1 HP
Max Engine Torque 13.8 ft-lbs. 13.8 ft-lbs.
Idle 1750 RPM 1750 RPM
Max RPM 3800 RPM 3800 RPM
Weight < 150 lbs. 120 lbs.
Tire Diameter 22 inches 22 inches
Vehicle Engineering Specifications
Suspension
Specification Specified by Designed
Suspension Travel 10 Team 10
Spring Rates
Front: 105 lb/in
Rear: 145 lb/in
Suspension
Synthesis
Front: 120 lb/in
Rear: 140 lb/in
Camber
Front: 5.0
Rear: 0.0
Team
Front: 5.0
Rear: 0.0
Bump Steer 0.0 Team 0.0
Weight < 65 lbs. Team ~50 lbs.
Steering
Specification Specified by Designed
Turning Radius 10 feet Team/Advisors 10.02 feet
Rack & Pinion Travel 4.25 inches Team 4.75 inches
Lock-to-Lock 1.5 turns ----- 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

Using hollow axles would at best save 0.5 lbs per axle
and would increase part cost

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


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


Loading: 4 Loading: 5
Front
Shocks:
Travel
20.275-
14.55
Spring Constant
Front:
105.3719
Spring
Constant
Front:
131.7149
Rear
Shocks:
Travel
20.00-
16.215
Travel
18.00-
12.00
6" Stroke
Force in Spring
Front:
903
Force in
Spring
Front:
1129
Force in Spring
Front:
832
Force in
Spring
Front:
1040
Travel
18.00-
12.00
6" Stroke
142.3406
Spring Constant
Rear:
Shock - Fox Podium X
Shock - Fox Podium X
Spring - 140#/IN, 10.5",
Red
Spring - 120#/IN, 10.5",
Red
Spring 120 lb/in
Front
Shocks:
Rear
Shocks:
lb/in
From Synthesis: Shock and Spring Analysis:
g's g's
lbs
lbs
lb/in 177.9258
Spring
Constant
Rear:
lb/in
lb/in
lbs
lbs
18.01 (Extended Length) x 6.00 (Stroke)
Spring 105 lb/in
3.79" Stroke
5.73" Stroke
Polaris Website
Spring 145 lb/in
Spring 140 lb/in
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 1 Inch 1.25 Inch
Diameter (in) 1 1.25
Wall (in) 0.075 0.075
c (in) 0.5 0.625
I moment (in
4
) 0.02346 0.04797
F
max
Bending (lbs) 156.5 256.0

A-Arm tube Length 15.875 in
Tubing Yield Strength 53 Ksi
Suspension Stress Analysis

y
= psi
g's t = 0.0625 in t = 0.125 in
lbs 1/16 in 1/8 in
lbs = 29013.33 psi = 14506.67 psi
P A = 2wt
y
A A = 0.75t
P P
0.75 F.S. = 1.85 F.S. = 3.70
1/8
Shear and Compression:
Mounting Bracket Stress Analysis:
in t =
53700
1360
680
2
t = 0.034 in
Dynamic Loading (P):
Weight of Car:
Loading:
t =
= F.S. =
A =
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 37.5 degrees
Inside Wheel Steering Angle 41.6 degrees
Ackerman Steering Angle 39.55 degrees
Turning Radius 10.02 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 analysis based on COM height, roll center, and spring rate
Vehicle will be rollover-resistant when cornering at reasonable speeds
0
5
10
15
20
25
30
0 5 10 15 20 25 30 35 40 45 50
M
a
x
i
m
u
m

S
a
f
e

V
e
l
o
c
i
t
y

(
m
p
h
)

Turning Radius (ft)
Dynamic Rollover Threshold
Torque Analysis
Based on front/rear weight distribution and torque at wheels
Result: Front wheels will stay on the ground under foreseeable
circumstances
0
200
400
600
800
1000
1200
1400
1600
0 5 10 15 20 25 30 35
R
e
s
i
s
t
i
v
e


T
o
r
q
u
e

(
l
b
-
f
t
)

Percent Grade
Torque vs. Incline
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
Jan 18 Jan 25 Feb 1 Feb 8 Feb 15 Feb 22 Mar 1 Mar 8 Mar 15 Mar 22 Mar 29 April 5 April 12
DESIGN
frame
suspension
steering
design review I Jan 20
braking
complete design Jan 25
PURCHASING PURCHASING
tubing
tools
drivetrain
suspension
brakes
drivetrain
steering
safety equipment
engine
nuts 'n' bolts
FABRICATION/ASSEMBLY FABRICATION/ASSEMBLY
tube bending
welding fixtures
fabricate frame
suspension
brakes
drivetrain
steering
safety equipment
design review II Feb 17
drivable vehicle Feb 28 Mar 13
bells and whistles
paint
competition prep
competition-ready Mar 28
design review III Mar 31
TESTING
on-road
off-road
competition April 8-11
design review IV April 21
activity
week
Feb 15 Feb 22 Mar 1 Mar 8 Mar 15 Mar 22 Mar 29
PURCHASING
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 Feb 17
drivable vehicle Feb 28 Mar 13
bells and whistles
paint
competition prep
competition-ready Mar 28
design review III Mar 31
activity
week
Budget
Original Budgeted
Retail Cost
Retail Cost Customer Cost
Competition Expenses $ 3,000.00 $ 3,100.00 $ 2,100.00
Vehicle System Costs
Frame $ 1,100.00 $ 1,100.00 $ 50.00
Powertrain $ 3,785.00 $ 6,290.34 $ 3,033.69
Suspension $ 2,178.29 $ 3,600.00 $ 1,648.00
Steering $ 345.00 $ 269.95 $ 269.95
Braking $ 1,124.09 $ 1,124.09 $ 653.00
Tires and Maintenance $ 396.00 $ 500.00 $ 200.00
Miscellaneous $ 500.00 $ 1,750.00 $ 1,000.00
TOTAL VEHICLE EXPENSES $ 9,428.38 $ 14,634.38 $ 6,854.64
Team Operation Expenses $ 1,450.00 $ 900.00 $ 900.00
Team Labor Expenses $ 151,350.00 $ 154,950.00 $ -
Total Anticipated Costs $ 165,228.38 $ 173,584.38 $ 9,854.64
Budget
Hourly Rate Extended Cost
Item Description Retail Rate
Customer
Rate
Quantity Retail Cost Customer Cost
Engineering Design & Analysis $75.00 $0.00 1300 $97,500.00 $0.00
Fabrication Machining Time $50.00 $0.00 30 $1,500.00 $0.00
Welding Fixtures $45.00 $0.00 20 $900.00 $0.00
Tube Bending $45.00 $0.00 6 $270.00 $0.00
Welding $45.00 $0.00 144 $6,480.00 $0.00
Assembly $45.00 $0.00 840 $37,800.00 $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
CVTech-IBC:
$232.00 CVT for $130.00
Tubing:
Tenaris Coiled Tubes 150 feet of tubing
QwikService Steel 200+ feet of various tubing and steel
Ariens:
$2,074.60 in parts for $371.69
Dana Transaxle, locking differential, and driveshaft components
The University of Tulsa Student Association
$1,000 towards travel costs to competition in South Carolina
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
Updated Retail
Cost
Customer Cost
Vehicle System Costs
Frame Tubing - Donated $ 750.00 $ 750.00 $ -
Tubing - Purchased $ 350.00 $ 350.00 $ 50.00
System Total $ 1,100.00 $ 1,100.00 $ 50.00
Powertrain Transaxle $ 1,320.00 $ 1,653.12 $ -
Engine $ 450.00 $ 628.00 $ -
CVT $ 130.00 $ 232.00 $ 130.00
Rear Drive Axles $ 1,000.00 $ 2,965.00 $ 2,503.69
Miscellaneous $ 885.00 $ 812.22 $ 400.00
System Total $ 3,785.00 $ 6,290.34 $ 3,033.69
Suspension Shocks $ 1,160.00 $ 1,700.00 $ 810.00
A-Arms $ 250.00 $ 800.00 $ 438.00
Wheel Uprights $ 768.29 $ 1,100.00 $ 400.00
System Total $ 2,178.29 $ 3,600.00 $ 1,648.00
Steering Rack and Pinion $ 98.00 $ 94.95 $ 94.95
Accessories $ 247.00 $ 175.00 $ 175.00
System Total $ 345.00 $ 269.95 $ 269.95
Braking $ 1,124.09 $ 1,500.00 $ 653.00
Tires and Maintenance $ 396.00 $ 500.00 $ 200.00
Miscellaneous $ 500.00 $ 1,750.00 $ 1,000.00
TOTAL VEHICLE EXPENSES $ 9,428.38 $ 15,010.29 $ 6,854.64
Original Retail
Cost
Updated Retail
Cost
Customer Cost
Competition Expenses
Travel to South Carolina Hotel $ 1,000.00 $ 1,100.00 $ 100.00
Transportation and More $ 1,000.00 $ 1,000.00 $ 1,000.00
TOTAL $ 2,000.00 $ 2,100.00 $ 1,100.00
Entry Fee $ 1,000.00 $ 1,000.00 $ 1,000.00
TOTAL COMPETITION EXPENSES $ 3,000.00 $ 3,100.00 $ 2,100.00
Vehicle System Costs
TOTAL VEHICLE EXPENSES $ 9,428.38 $ 15,010.29 $ 6,442.95
Team Operation Expenses
Driving/Safety Gear $ 800.00 $ 200.00 $ 200.00
Team Uniforms $ 300.00 $ 300.00 $ 300.00
Office Supplies $ 100.00 $ 100.00 $ 100.00
Fabrication Tools $ 250.00 $ 300.00 $ 300.00
TOTAL OPERATION EXPENSES $ 1,450.00 $ 900.00 $ 900.00
Team Labor Expenses
Total Engineering $ 97,500.00 $ 97,500.00 $ -
Total Fabrication $ 43,350.00 $ 46,950.00 $ -
Total Testing $ 10,500.00 $ 10,500.00 $ -
TOTAL LABOR EXPENSES $ 151,350.00 $ 154,950.00 $ -
Total Anticipated Costs $ 165,228.38 $ 173,960.29 $ 9,442.95