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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HOQ
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% Kyle
Cut/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% Keegan
Mount 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% Kyle
Fabricate 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 !!!