Baja Team 2015 Final Report

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  • University of Alaska Anchorage

    Society of Automotive Engineers

    2015 Baja Team

    ME A438 Fall 2014 Senior Design Report

    Design Team Members:

    Galen Baumgartner Devon Jones Jun Mendoza Valisa Hansen Elena Stutzer

    Faculty Advisors:

    Dr. Jeffrey Hoffman & Dr. Todd Petersen

    Date: Friday, December 5, 2014

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    Report Contents

    1.0 Introduction ............................................................................................................................... 4

    1.1 Project Statement.............................................................................................................. 4

    1.2 Project Scope .................................................................................................................... 5

    2.0 Methods..................................................................................................................................... 5

    2.1 Frame ..................................................................................................................................... 6

    2.1.1 Material ........................................................................................................................... 7

    2.1.2 Finite Element Analysis .................................................................................................. 8

    2.1.3 Existing Testing ............................................................................................................ 11

    2.1.4 Weight .......................................................................................................................... 14

    2.1.5 Ergonomics ................................................................................................................... 15

    2.2 Front Suspension and Steering ............................................................................................ 15

    2.2.1 Design Parameters ........................................................................................................ 15

    2.2.2 Impact Force ................................................................................................................. 16

    2.2.3 Frontal Impact............................................................................................................... 17

    2.2.4 Suspension Geometry ................................................................................................... 17

    2.2.5 Simulation ..................................................................................................................... 19

    2.2.6 Experiment.................................................................................................................... 20

    2.3 Controls and Brakes Systems .............................................................................................. 22

    2.3.1 Basis of Brake Design .................................................................................................. 23

    2.3.2 Hydraulic Brake System ............................................................................................... 23

    2.3.3 Pedal Design ................................................................................................................. 26

    2.3.4 Gear Shifter Design ...................................................................................................... 28

    2.4 Rear Suspension .................................................................................................................. 29

    2.4.1 Design Criteria .............................................................................................................. 29

    2.4.1 Suspension Type ........................................................................................................... 29

    2.4.2 Finite Element Analysis ................................................................................................ 30

    2.4.3 Trailing Arm ................................................................................................................. 31

    2.4.4 Bearing Carrier ............................................................................................................. 31

    2.4.5 Mounting Devices......................................................................................................... 31

    3.0 Results ..................................................................................................................................... 32

    3.1 Finalized Frame ................................................................................................................... 33

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    3.1.1 Frame Analysis Results ................................................................................................ 33

    3.2 Front Suspension Study Results .......................................................................................... 42

    3.2.1 Front Suspension Geometry ......................................................................................... 42

    3.2.2 Finite Element Analysis ................................................................................................ 44

    3.3 Control Systems Anlalysis .................................................................................................. 47

    3.4 Rear Suspension Iterations .................................................................................................. 51

    3.4.1 Bearing Carrier Results ................................................................................................ 52

    3.4.2 Trailing-Arm Results .................................................................................................... 52

    3.4.3 Mounting Device Results ............................................................................................. 53

    4.0 Conclusion .............................................................................................................................. 55

    5.0 References ............................................................................................................................... 55

    6.0 Appendix A: Material Certification ........................................................................................ 56

    6.1 Appendix B: Roll Cage Equivalency Calculations ................................................................. 57

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    1.0 Introduction

    Baja SAE (Society of Automotive Engineers) is an international collegiate design

    competition sponsored by the Society of Automotive Engineers. The competition is held every

    year and presents engineering students with the challenge of designing a mechanical system and

    implementing that design through the construction of an off-road vehicle. The 2015 Baja Car

    will be the fifth car designed, assembled and raced by University of Alaska Anchorage (UAA)

    engineering students in the Baja SAE annual competition.

    This year, a complete redesign of the car was the primary focus of the Baja Team.

    Improvement of five key systems, the chassis (frame), breaks, shifter, front suspension and rear

    suspension, was the target of this redesign. These subsystem improvements were based on

    assessment of the previous cars raced by UAA, as the ultimate goal of the 2015 UAA Baja Team

    is to score within the top 20% upcoming Baja SAE competition.

    Design was divided between sub-teams that focused on each of the five subsystems. Each

    subsystem team worked with the group as a whole to meet mutual team goals. Each team

    produced a SolidWorks model of its subsystem, which was then assembled into the model of the

    entire car. This model allowed the Team to compile stress/strain data and improve upon the

    design of the car as the project progressed. SolidWorks Simulation was used to perform finite

    element analysis and motion analysis on the vehicle to optimize the performance and efficiency

    of each component and subsystem.

    1.1 Project Statement

    The Society of Automotive Engineers hosts an annual design competition for engineering

    students. The competition challenges participants to design and build an off-road vehicle. In May

    2015, the Baja Team will race the fifth car designed and assembled by students in the UAA

    College of Engineering.

    This year, the car was to be redesigned using the experiences of the past four UAA Baja

    Teams, as well as advising from the faculty and staff of the UAA College of Engineering. The

    Teams focus was primarily on the redesign of five key systems: the chassis (frame), breaks,

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    shifter, front suspension and rear suspension. The Team assessed the performance of the

    previous UAA Baja SAE cars, placing the most emphasis on the car from last year (2014), to

    define the particular strengths and weaknesses that needed to be addressed for each individual

    subsystem. The 2015 Team improved these systems, identified as the cars weakest components,

    in order to design a more competitive vehicle.

    1.2 Project Scope

    The primary goal of the 2015 UAA Baja Team is to score within the top 20% at the May 27-

    30, 2015 SAE Baja competition in Portland, Oregon. To accomplish this goal, the group was

    divided into sub-teams.

    The task of design was divided by subsystem. Each team had a primary focus: the frame,

    front suspension, rear suspension, shifter and brakes. Individual teams closely followed the SAE

    Baja competition guidelines as stated in the official rule handbook