F13-60-BAJA PROPOSALSAE SALUKI FRAME DESIGN

Team MembersAustin Lewandowski (ME) (PM)Thang Tran (ME)Preston Mathis (ME)Keegan Lohman (ME)Kyle Koester (ME)Steven Baldwin (ME)

Outline• Executive Summary (TT)• Design Approach – HOQ (PM)• Design Approach – Block Diagram (KL)• Material Selection (PM)• Frame Design Optimization (KL)• Finite Element Analysis (FEA) (KK)• Timeline – AIL (AL)• Resources Needed (SB)• Summary (AL)

Executive SummaryProject Background

• Building an off road vehicle to SAE specs, with intent to sell to general public

• International competition of 100+ schools Problem Statement:

Previous frame designs have been overbuilt with material that was too thick, or supported with unnecessary members adding extra weight.

Goals:• Focus efforts on weight reduction of 100 pounds.• Can be achieved through applying principles of material selection,

frame design optimization, and Finite Element Analysis (FEA)

Executive SummaryTeam Responsibilities:• Material Selection (PM)• Frame Design Optimization (KL, SB, TT)• FEA (AL, KK)

Bottom Line• The overall project is estimated to cost approximately $855.

The project will begin on January 14, 2014, and will be completed by March 7, 2014.

Design Approach

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Block Diagram

Material Selection

Ultimate Tensile Strength, psi 97,200

Yield Strength, psi 63,100

Elongation 25.5%

Rockwell Hardness B92

4130 Chromoly• The material selected for the use

of this years SAE baja frame will be 4130 “chromoly” steel. Although it is more expensive than typical 1018 steel, the durability, ease of welding, and superior strength to weight ration makes it a prime material for off-road applications. A majority of other teams use this material and have had great success in past competitions.

[1] 4130 (Chromoly) Normalized Alloy Steel [Internet] OnlineMetals.com, 2013, http://www.onlinemetals.com/alloycat.cfm?alloy=4130, [10/24/13].

[1] 4130 (Chromoly) Normalized Alloy Steel

Design Optimization• Tube frame chassis:

Front End

Rear Roll Hoop (RRH)

Base

Design Optimization: Side View

Template

Design Optimization: Auxiliary View

Finite Element Analysis (FEA)• Performing static representation of dynamic loading to find

failure modes of frame• Models followed from other teams/auto industry• Goals are to locate areas of minimum stress and reduce member

size• Top, front, side impacts, roll over

Time Line

AILTask Name Duration Start Finish % Complete Resource Names

Phase 2 Work 0%RRH Jig 2 days Mon 1/6/14 Tue 1/7/14 0% Preston

Cut/Bend/Cope/Weld RRH 7 days Tue 1/7/14 Wed 1/15/14 0% Steven

BF Jig 2 days Mon 1/13/14 Tue 1/14/14 0% Thang

Cut/Bend/Cope/Weld base frame 5 days Tue 1/14/14 Mon 1/20/14 0% Austin

Front End Jigs 2 days Fri 1/24/14 Mon 1/27/14 0% Austin

Cut/Bend/Cope/Weld front end 5 days Mon 1/27/14 Fri 1/31/14 0% Keegan

Rear End Jigs 3 days Mon 2/3/14 Wed 2/5/14 0% KyleCut/Bend/Cope/Weld rear end 9 days Thu 2/6/14 Tue 2/18/14 0% Keegan

Cockpit Support Jigs 3 days Thu 2/6/14 Mon 2/10/14 0% Austin

Cut/Bend/Cope/Weld Cockpit overhead and support members 4 days Mon 2/17/14 Thu 2/20/14 0% Preston

Finish weld all frame members 2 days Fri 2/28/14 Mon 3/3/14 0% KeeganMount engine and transmission 0% Steven

Mount seat/safety harness mounts 0% Kyle

Cut/Bend/Cope/Weld front A-arm uppers 0% Austin

Cut/Bend/Cope/Weld front A-arm lowers 0% Austin

Cut/Bend/Cope/Weld trailing arms 0% Preston

Machine Knuckles 0% Shop members

Machine spindles 0% Shop members

Mount front suspension 0% Shop members

Mount rear suspension 0% Shop members

Design shifter mounts 0% KyleFabricate shifter subassembly 0% Steven

Design brake control subsystem 0% Thang

Fabricate brake control mount subsystem 0% Thang

Run brake lines/assemble brake subsystem 0% Shop members

Design accelerator control subsystem 0% Preston

Fabricate accelerator control subsystem 0% Preston

Fabricate steering subsystem 0% Keegan

Assemble wiring harness 0% Shop members

Resources NeededMaterial needed Quantity Price/unit Total Price Location Location Sub Total

Frame            1"x0.065 Chromoly Tube 40 $3.19 $127.60      1"x0.049 Chromoly Tube 30 $3.27 $98.10      1"x0.035 Chromoly Tube 20 $3.44 $68.80      

1.25"x0.065 Chromoly Tube 40 $3.89 $155.60      1/2" x0.049 Chromoly Tube 10 $3.19 $31.90      3/8"x0.049 Chromoly Tube 10 $3.22 $32.20                  $514.20

Mounting Tabs            .125"x12"x12" Chromoly Sheet 5 $39.46 $197.30      .032"x48"x120" Aluminum Sheet 1 $143.14 $143.14                  $340.44

Tools            

Dewalt hand grinder 2 2   On hand Baja Shop  

Bench grinder 1 1   On hand Baja Shop  

JD^2 tubing bender 1     On hand Baja Shop  Horizantal band saw 1     On hand Baja Shop  Vertical band saw 1     On hand Baja Shop  End mill 1     On hand Baja Shop  

2 axis CNC plasma table 1     On hand Baja Shop  

TIG welder 1     On hand Baja Shop  

Grinding disks 4     Lowes Baja Shop  Grinding cut off wheels 6     Lowes Baja Shop  TIG weld rod       Airgas Baja Shop  Argon gas 1     Airgas Baja Shop  

1.25" Carbide end mill 1     On hand Baja Shop  

1" Carbide end mill 1     On hand Baja Shop   Total           $854.64

Summary• Considering our material selection, design optimization, and

use of FEA will allow us to reduce the weight of the frame.• Our goal is to start on January 14th and finish on March 7, and

we will achieve this by sticking to our timeline.

Thank you for listening !!!