F13-60-BAJA PROPOSAL SAE SALUKI FRAME DESIGN Team Members Austin 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 Summary  Project 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 Summary  Team 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 HOQ

Block Diagram

Material Selection Ultimate Tensile Strength, psi 97,200 Yield Strength, psi63,100 Elongation25.5% Rockwell HardnessB 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, [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

AIL Task NameDurationStartFinish% CompleteResource Names Phase 2 Work0% RRH Jig2 daysMon 1/6/14Tue 1/7/140%Preston Cut/Bend/Cope/Weld RRH7 daysTue 1/7/14Wed 1/15/140%Steven BF Jig2 daysMon 1/13/14Tue 1/14/140%Thang Cut/Bend/Cope/Weld base frame5 daysTue 1/14/14Mon 1/20/140%Austin Front End Jigs2 daysFri 1/24/14Mon 1/27/140%Austin Cut/Bend/Cope/Weld front end5 daysMon 1/27/14Fri 1/31/140%Keegan Rear End Jigs3 daysMon 2/3/14Wed 2/5/140%Kyle Cut/Bend/Cope/Weld rear end9 daysThu 2/6/14Tue 2/18/140%Keegan Cockpit Support Jigs3 daysThu 2/6/14Mon 2/10/140%Austin Cut/Bend/Cope/Weld Cockpit overhead and support members4 daysMon 2/17/14Thu 2/20/140%Preston Finish weld all frame members2 daysFri 2/28/14Mon 3/3/140%Keegan Mount engine and transmission0%Steven Mount seat/safety harness mounts0%Kyle Cut/Bend/Cope/Weld front A-arm uppers0%Austin Cut/Bend/Cope/Weld front A-arm lowers0%Austin Cut/Bend/Cope/Weld trailing arms0%Preston Machine Knuckles0%Shop members Machine spindles0%Shop members Mount front suspension0%Shop members Mount rear suspension0%Shop members Design shifter mounts0%Kyle Fabricate shifter subassembly0%Steven Design brake control subsystem0%Thang Fabricate brake control mount subsystem0%Thang Run brake lines/assemble brake subsystem0%Shop members Design accelerator control subsystem0%Preston Fabricate accelerator control subsystem0%Preston Fabricate steering subsystem0%Keegan Assemble wiring harness0%Shop members

Resources Needed Material neededQuantityPrice/unitTotal PriceLocation Sub Total Frame 1"x0.065 Chromoly Tube40$3.19$ "x0.049 Chromoly Tube30$3.27$ "x0.035 Chromoly Tube20$3.44$ "x0.065 Chromoly Tube40$3.89$ /2" x0.049 Chromoly Tube10 $3.19 $ /8"x0.049 Chromoly Tube10 $3.22 $32.20 $ Mounting Tabs.125"x12"x12" Chromoly Sheet5$39.46$ "x48"x120" Aluminum Sheet1$ $ Tools Dewalt hand grinder22 On handBaja Shop Bench grinder11 On handBaja Shop JD^2 tubing bender1 On handBaja Shop Horizantal band saw1 On handBaja Shop Vertical band saw1 On handBaja Shop End mill1 On handBaja Shop 2 axis CNC plasma table1 On handBaja Shop TIG welder1 On handBaja Shop Grinding disks4 LowesBaja Shop Grinding cut off wheels6 LowesBaja Shop TIG weld rod AirgasBaja Shop Argon gas1 AirgasBaja Shop 1.25" Carbide end mill1 On handBaja Shop 1" Carbide end mill1 On handBaja 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 14 th and finish on March 7, and we will achieve this by sticking to our timeline.

Thank you for listening !!!