Nick Bloom Logan Kibler Philip Ritenour Scott Miner Matt Susa Team “GT 1” Baja SAE - #48 car Collegiate Design Series Society of Automotive Engineers Part 1/2 Nick Bloom Logan Kibler Philip Ritenour Scott Miner Matt Susa EGR 481/482 Senior Design Progress Report January 20, 2010

Overview of Presentation Competition abstract & description Goals Cost & fundraising Design Remaining work Acknowledgements Questions

Competition Abstract Exists “to simulate real-world engineering design projects and their related challenges.” (10.1, 2010 Baja SAE Rules)

Project Description “Teams must design, build, test, promote, and compete with a vehicle within the limits of the rules.” (10.1, Rules) Teams compete for manufacturing acceptance by a fictitious firm Competition location: Western Washington University Bellingham, WA May 19-22, 2010

Video Clip from University of Louisville 2009 Baja SAE team (play 0:04 - 1:00) www.youtube.com/watch?v=k6zpluQRgu4

2010 Baja SAE - Dynamic Events

2010 Baja SAE - Endurance Event

Competition Scoring Breakdown 2010 Western Washington Competition Scoring Static Events (300 points) Points Design Report 50 Evaluation 100 Cost Report & Production Cost Sales Presentation Dynamic Events (700 points) Acceleration 75 Hill Climb Maneuverability Rock Crawl Endurance 400 Total 1000

Goals Design goals Performance goals 400 pound curb weight 12 inches of ground clearance Short wheel base Well-balanced Durable Performance goals Successfully completing all events

Fundraising Efforts IA office – engineering alumni mailing for Baja SAE, AISC Steel Bridge, and Solar Splash teams (~$1,000 raised for each) IA office - targeted corporate mailing sent out (planning phone follow-up to these and many more companies) Planning a t-shirt sale Approaching GCSU for direct support

Competition Entrance Fee $1,000.00 Travel Expenses $3,750.00 Cost Estimate   Category Amount Competition Entrance Fee $1,000.00 Travel Expenses $3,750.00 Vehicle Parts & Fabrication $4,750.00 Safety Equipment $500.00 Grand Total $10,000.00

Design Overview Frame Drive train Suspension

Frame Design

Initial Decisions Examined other Baja vehicles for ideas Fairmont State Grove City Oregon State Simplistic frame geometry / compact nature of the vehicle. Team has placed in the top 10 consistently, and won 1st place at last year’s regional competition.

Oregon State Baja SAE Vehicle

Purpose/Function Structural rigidity and stability to vehicle Protects driver Rollover injury Significant impacts Large suspended objects Mounting location for seat and harness

Design Considerations SAE specified parameters Required members (i.e. lateral diagonal bracing, side impact member, under seat member) Rear roll hoop width (≥ 29” at 27” above seat) 6” minimum clearance from top of helmet of tallest person to top of roll cage Gusseting joints where continuous tubing is not used Butt joints must be reinforced with welded sleeve

Design Considerations Steel Equivalent bending strength and stiffness of ASTM 1018 steel with 1” O.D. and .12” wall thickness (31.5) Via calculations, determined sufficient replacement to be 4130 chromoly, 1.25” O.D. and .065” wall thickness

Design Considerations Group specified considerations Adequate width to accommodate hand clutch Room for feet for accelerator and brake pedals Proper seat mounting Shocks, bumps, people’s legs falling asleep Steel providers McMaster Carr, OnlineMetals.com, O’Neil Steel, KenMac Metals, Steel Sales of Pittsburgh, Youngstown Pipe & Supply Co., Trinity Metals and Welding, Dillsburg Aeroplane Works McMaster- $7.41/foot OnlineMetals.com- $5.41/foot Dillsburg Aeroplane Works- $2.38/foot

Design Considerations Steel purchased 4130 steel tubing 1.25” OD, .065” wall thickness 4130 steel tubing 1.25” OD, .049” wall thickness 4130 steel tubing 1.25” OD, .035” wall thickness Section 31.2.1 states that only certain required members must have a minimum thickness of .065”; all others can be as small as .035” Fabrication method: MIG (GMAW) Welding

Design Conception Measurements taken by placing tallest driver in simulated driving position Also used to integrate front suspension with front of body and pedals

Frame Concepts – RRH (1/2)

Frame Concepts – RRH (2/2)

Frame Concepts – RRH & Back

Frame Concepts – Drive System

Future Goals Finish design of front half of vehicle Begin cutting, bending, welding, etc. Mate frame to suspension components Install engine and drive train components Finish smaller details (pedals, controls, steering, etc.)

Design Future Fairmont State University Baja SAE frame