Team F13-60-Baja Frame Design

Report
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
3
9
Marketability
5
Weight
4
Durability
3
Performance
3
Tech Importce.
9
3
1
3
9
Rural King Go
Cart
5
Polaris Razor
Safety
Saluki Eng. Co
3
Geometry/ Des.
9
FEA
Design Quality
2
Mat. Selection
Dimensions
Size
Cost
Import 1-5
HOQ
3
9
3
2
3
9
1
9
9
3
1
3
1
5
4
2
4
3
3
9
3
2
3
3
9
9
5
3
1
3
5
2
9
57 150 51 108 90 50
Block Diagram
Material Selection
[1] 4130 (Chromoly) Normalized Alloy Steel
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].
Ultimate Tensile
Strength, psi
97,200
Yield Strength, psi
63,100
Elongation
25.5%
Rockwell Hardness
B92
Design Optimization
• Tube frame chassis:
Rear Roll Hoop (RRH)
Front End
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 Name
Duration
Start
Finish
% Complete
Resource Names
Phase 2 Work
RRH Jig
2 days
Mon 1/6/14
Tue 1/7/14
0%
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
Cut/Bend/Cope/Weld rear end
3 days
9 days
Mon 2/3/14
Thu 2/6/14
Wed 2/5/14
Tue 2/18/14
0%
0%
Kyle
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
Mount engine and transmission
2 days
Fri 2/28/14
Mon 3/3/14
0%
0%
Keegan
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
Fabricate shifter subassembly
0%
0%
Kyle
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 Needed
Material needed
Frame
1"x0.065 Chromoly Tube
1"x0.049 Chromoly Tube
1"x0.035 Chromoly Tube
1.25"x0.065 Chromoly Tube
1/2" x0.049 Chromoly Tube
3/8"x0.049 Chromoly Tube
Quantity
Price/unit
40
30
20
40
10
10
Total Price
$3.19
$3.27
$3.44
$3.89
$3.19
$3.22
Location
Location
Sub Total
$127.60
$98.10
$68.80
$155.60
$31.90
$32.20
$514.20
Mounting Tabs
.125"x12"x12" Chromoly Sheet
.032"x48"x120" Aluminum Sheet
5
1
$39.46
$143.14
$197.30
$143.14
$340.44
Tools
Dewalt hand grinder
Bench grinder
JD^2 tubing bender
Horizantal band saw
Vertical band saw
End mill
2 axis CNC plasma table
TIG welder
Grinding disks
Grinding cut off wheels
TIG weld rod
Argon gas
1.25" Carbide end mill
1" Carbide end mill
Total
2
1
1
1
1
1
1
1
4
6
1
1
1
2
1
On hand
On hand
On hand
On hand
On hand
On hand
On hand
On hand
Lowes
Lowes
Airgas
Airgas
On hand
On hand
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
Baja Shop
$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 !!!

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