1. SAE Baja Frame Design
Brandt Lamonte, Luke Blocker, Alexandria Williams, Kyle Richert
Advisor: Ho-Hoon Lee

2. SAE Baja Competition
Intercollegiate design competition by Society of Automotive Engineers (SAE)
Challenge is to build a small vehicle that can withstand harsh terrain
Build must follow certain rules and guidelines set forth by SAE (Size, Capability, Human Factors, etc.)
Frame
Frame Construction and Material
4130 Tubular space frame with 1020 steel brackets and tabs
Joining method and material
GTAW ER70-S2 filler
Targets (Torsional Stiffness or other)
2000 lbs-ft/deg  (2712 N-m/deg)
Torsional stiffness and validation method
2100 lbs-ft/deg (2847  N-m/deg) CAE beam model, 1800 lbs-ft/deg (2440 N-m/deg) physical test
Bare frame weight with brackets and paint
55 lbs (25kg)

3. Our Project
Team consists of 9 members, split into 4 different design groups (Frame, Suspension, Steering, Power)
Our group will focus on the design of the frame.
Group will be split into 2 subgroups to provide 2 individual frame designs
Complete Solidworks 3D design with stress analysis

4. Purpose The project will:
Demonstrate the students’ ability to research, plan, and orchestrate the designing of a frame with given parameters
Give the opportunity for M.E.T. students to apply knowledge in a real-world assignment
Test the students’ ability to work within a group and communicate clearly, concisely, and professionally
Create a well designed and efficiently built Baja buggy frame

5. Method (Brandt & Luke) Research to gain understanding
Decide desirable tubing size
Make reasonable assumptions to begin modeling
Stress analysis
Select material and estimate cost
Mesh frame concept with other groups’ component designs
Design mounting interfaces
Final stress analysis
Final modifications

6. Deliverables (Brandt & Luke)
Solidworks 3-D frame design
Complete stress analysis of frame
Design of mounting interfaces between Baja team groups
Material Selection
Cost analysis

7. Tentative Timeline (Brandt & Luke)
February 24th
Proposal presentation
Brandt & Luke
February 25th - March 10th
Research and initial design
March 11th - 17th
Design alongside Suspension team and adjustments
March 18th - March 31st
Research and rough draft Design
April 1st - April 7th
Stress Analysis
Luke
April 8th - April 15th
Develop 3D Model of final draft in Solidworks
April 16th - April 21st
Design mounting interface
Brandt
April 22nd - April 23rd
Material selection
April 24th - April 27th
Cost Analysis
April 28th - May 4th
Create final proposal and presentation
May 5th
Present final presentation

8. Method (Alex & Kyle) Estimate respectable dimensions for
driver’s comfort
placement of suspension
configuration of powertrain
steering components
Research materials
tensile strength
round and square tubing
weight
machinability
Design 3-D model using Solidwork or Comsol with force analysis
Cost analysis

9. Deliverables
(Alex & Kyle) Research a metal material that complies with the SAE Mini Baja regulations
(Alex) Provide accommodations for other Baja components (powertrain, suspension, and steering)
(Kyle) Understand how to create using reverse engineering
(Alex & Kyle) Create 3D model analyzing forces and complete stress analysis
(Kyle) Cost analysis

10. Tentative Timeline (Alex and Kyle)
February 7-23
Meet with advisor, group selection, create proposal and presentation
February 24
Presentation Day
February 25-March 10
Research and rough draft Design
March 11-17
Design alongside other teams and adjustments
March 18- April 7
Develop 3D Model of rough draft in Solid works or Comsol
April
Develop 3D Model of final draft in Solid works or Comsol
April 22-May 4
Create final proposal and presentation
May 5
Present final presentation

11. QUESTIONS OR
CONCERNS