EngineeringDesignPortfolio

Andrew Bai

• Designed two custom engine cradles for an MG B-Series engine and a Mazda B6ZE engine

Spring 2015 – Engine Dolly Projects

• Designed a custom dynamometer stand to connect a Mazda B6ZE engine to the school’s dynamometer

• Used Strength of Materials principles to accurately determine the correct diameter of the connecting shaft so as to not fail when subjected to a maximum engine torque of 115 ft-lbs

Fall 2015 – Engine Dynamometer Stand Project

• Designed a brake pedal assembly for a Formula SAE race car

Fall 2015 – Formula SAE Brake Pedal Project

• Designed a Formula SAE chassis that complied with the 2016 competition rules

Fall 2015 – Formula SAE Chassis Project

• Added reinforcement bars to strengthen the torsional rigidity of the chassis

• Used Finite Element Analysis to validate chassis rigidity strength

Results• Chassis achieved a 492,224 in-lbs/rad rigidity

in the front and a 777,112 in-lbs/rad in the rear while weighing 78.37 lbs

Fall 2015 – Formula SAE Wheel Center Project• Designed a lightweight wheel center for a

Formula SAE car

• Used Finite Element Analysis to test wheel center under real-life loads to validate strength and design

Results• Wheel Center was able to withstand a 584 in-lb

braking force and a 192.5-lb lateral force on the bottom while weighing 0.73 lbs

Spring 2016 – IndyCar Sway Bar Link Project• Reverse-engineered a defective sway bar end link of an

IndyCar race car

• Used Finite Element Analysis to find a concentrated stress area on the end link blade

(bottom left photo)

• Modified blade section to evenly spread stress area (bottom right photo)

Spring 2016 – IndyCar Sway Bar Link Project (Drawings)

• Converted an IndyCar U-Style sway bar system into a T-Bar system while trying to match spring rates as close as possible

Spring 2016 – IndyCar Sway Bar Design Project

• Reverse-engineered several individual parts for FEA testing (single-blade links, center tube, and double-blade link)

Spring 2016 – IndyCar Sway Bar Design Project (FEA Testing)

Setting Force Applied (lbs) Displacement (in) k(Blade) (lbs/in)k(effective)

(lbs/in)

Full Soft 125 0.1387 901.226 443.764

250 0.2774 901.226 443.764

375 0.4178 897.559 441.986

500 0.5559 899.442 442.899

Medium 125 0.0988 1265.823 619.483

250 0.1975 1265.823 619.483

375 0.2962 1266.036 619.585

500 0.3966 1260.716 617.036

Full Hard 125 0.0162 7730.365 3413.316

250 0.0323 7732.756 3414.249

375 0.0485 7731.959 3413.938

500 0.0647 7732.756 3414.249

Spring 2016 – IndyCar Sway Bar Design Project (FEA Testing)

Setting Force Applied (lbs) Displacement (in) k(bar) (lbs/in) k(effective) (lbs/in)

Full Soft 125 0.0323 3868.771 591.633

250 0.0646 3868.771 591.633

375 0.0996 3763.927 586.635

500 0.1292 3869.969 591.689

Medium 125 0.0234 5341.880 646.129

250 0.0468 5341.880 646.129

375 0.0702 5341.880 646.129

500 0.0936 5341.310 646.113

Full Hard 125 0.0065 19113.150 782.523

250 0.0131 19113.150 782.523

375 0.0196 19113.150 782.523

500 0.0262 19113.150 782.523

Fall 2016 – Mazda Miata Radiator Duct Project

• Designed and fabricated a custom radiator duct for a 1991 Mazda Miata race car for effective engine cooling

Fall 2016 – Mazda Miata Front Splitter Project

• Designed a custom front splitter assembly for a 1991 Mazda Miata with 1.50 inches of height adjustability and 6 degrees of angle adjustability

• Maintained a lightweight design by using 2024 and 6061 aluminum for the uprights, brackets, and turn buckles and aluminum honeycomb for the base

Fall 2016 – Mazda Miata Front Splitter Project(Conceptual Drawings)

Fall 2016 – Mazda Miata Front Splitter Project(Conceptual Modeling)

Fall 2016 – Mazda Miata Front Splitter Project(Initial Design)

Fall 2016 – Mazda Miata Front Splitter Project(Final Design)

Fall 2016 – Mazda Miata Front Splitter Project(Final Design - Details)

• Designed a chassis and roll bar assembly prototype for the 2017 Shell EcoMarathon Competition in which the roll bar could withstand a 700-Newton impact from any direction and extend 5 centimeters around the driver’s helmet for adequate crash protection

Fall 2016 – Shell EcoMarathon Chassis Project