TEAM MEMBERS: Chad Chandler Joe Cofer Nathan Eramian Francis Hauris Jeff Wong

BACKGROUND  ORIGINATED AT USC IN 1976 RUN BY SAE  COMPETITIONS STATIC EVENTS DYNAMIC EVENTS EVENTPOINTS STATIC300 Design Report50 Design Evaluation100 Cost Report15 Production Cost85 Presentation50 DYNAMIC700 Acceleration75 Pulling75 Maneuverability75 Rock Crawl75 Endurance400 TOTAL1000

 NEW FRAME DESIGN  REVAMPED SUSPENSION KINEMATICS  COMPLETE GEARBOX DESIGN  CUSTOM GEARS  CUSTOM SHAFTS

CRITERIONPRIORITYDESIGN REGIMENTS HANDLINGESSENTIAL -Unsprung to sprung optimization -Favorable weight distribution -Low CG -Congruent suspension kinematics AGILITYESSENTIAL -Great power to weight ratio -Efficient gear train -Low GVW RELIABILITYHIGH -CNC fabricated frame -Accurate FEA MANUFACTURABILITYDESIRED -Simplistic design -Less joints -Multipurpose beams

SUSPENSION DESIGN CONGRUENT KINEMATICS DOUBLE WISHBONE FRONT TRAILING ARM REAR TESTING MODES BUMP ROLL STEER

SUSPENSION ANALYSIS LSA COMPLIANCE SOLVER GENERATED FBD FOR ALL SUSPENSION COMPONENTS USEFUL FOR FUTURE FEA ESTABLISHES WORKING LOADS SHOCK PRELOADS

4130 N CHROMOLY AUTODESK INVENTOR

Force Applied Maximum Deflection Maximum Bending Stress Allowable Yield Stress Optimizations Made Front Collision 3.6G ≈ 2500lbs in.59,100 psi. 63,100 psi.N/A Rollover 3.2G ≈ 2250lbs in.59,200 psi. 63,100 psi.N/A Side Impact Collision 3G ≈ 2100lbs in.62,100 psi. 63,100 psi. Increase tube size on side members from (1/0.035) to (1/0.065) Torsional Rigidity 5000lb· in in.30,700 psi. 63,100 psi.N/A

FRONT COLLISION – 3G’s

ROLLOVER IMPACT – 3G’s

SIDE IMPACT COLLISION – 3G’s

TORSIONAL RIGIDITY 377 ft ·lb/deg

COMPONENTSPECS Engine -10hp ft·lbs -Governed at 3800 RPM’s CVT (Drive Ratio) Gearbox: ~ Reduction 8.29 Max mph 35 Max Torque (lb·ft) 470 Min Safety Factor 4.6

GEARS CUSTOM GEARS ROBUST OPTIMIZED FOR SPACE

SHAFT DESIGN SQUARE SPLINES RETAINING GROOVES HEAT TREATED STEEL ALLOY ANGULAR CONTACT BEARINGS

GEARBOX CASING EFFICIENT DESIGN LIGHT-WEIGHT ALUMINUM MOUNTING SIMPLICITY

18lbs

SOLIDWORKS FEA USED TO SIMULATE REAL STRESS CONDITIONS

ItemQuantityPriceTotal cost VR3 Engineering Frame Machining 1$1, Mcmaster Carr.com Bearing4$13.95$55.80 Fastenal Snap-ring10$0.53$5.33 Applied Industrial Technologies Stock Gears1$ Norfolk Machine Casing1$2, Norfolk Machine Keyed Stock Gear/Shaft 1$1, Eastern Marine Grease Seal3$4.15$12.45 Fastenal Shaft1$44.43 Tax $ Total$4,093.28

ME 435 PROJECTS