SEC
Saluki Engineering Company
Proposal For:
F13-60-Baja
SAE Saluki Baja
Submitted:
November 21, 2013
Team Members:
Austin Lewandowski (PM)
Keegan Lohman
Steven Baldwin
Preston Mathis
Thang Tran
Kyle Koester
November 21, 2013
Technical Advisor:
James C. Mabry
F13-60-Baja
SOUTHERN ILLINOIS UNIVERSITY CARBONDALE
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
ME 495A – SENIOR ENGINEERING DESIGN
SAE SALUKI BAJA FRAME DESIGN
F13-BAJA-60
DATE SUBMITTED: November 19, 2013
SUBMITTED TO: SALUKI ENGINEERING COMPANY
TEAM MEMBERS:
Austin Lewandowski (PM) [AL]
Kyle Koester [KK]
Keegan Lohman [KL]
Thang Quang Tran [TT]
Steven Baldwin [SB]
Preston Mathis [PM]
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F13-60-Baja
SAE Saluki Baja
Southern Illinois University
1230 Lincoln Drive
Carbondale, IL 62901-6603
500 West Freeman
Apt. 5
Carbondale IL, 62901
(309) 370-9774
Austin27ski@gmail.com
Dear Saluki Engineering Company:
Thank you for including us in the bid for the project to redesign the 2013-2014 Baja frame,
attached is the proposal. The frame design will be in accordance with SAE 2014 rules and
specifications, and will be ready for competition on May 22, 2014.
The project will be divided into five subsystems including front end, cockpit, and rear end
design, as well as finite element analysis, and material selection. Multiple design considerations
have been taken into account, and we look forward to providing you with a high performance,
durable, and most of all safe vehicle for competition.
We look forward to working with you, and exceed all of your expectations. If you have any
questions or concerns about this proposal, feel free to contact Austin27ski@gmail.com or by
phone at (309) 370-9774 at any time.
Sincerely,
Austin Lewandowski
Project Manager- SAE Saluki Baja Frame Design
Saluki Engineering Corporation
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F13-60-Baja
II. Executive Summary
Each year the Society of Automotive Engineers hosts a competition in which engineering
students design, build, and compete against engineering students from all over the world. This is
the third year that the Southern Illinois University Saluki Baja team has competed. Weight and
suspension design problems have been addressed by previous teams. Last year, the team
corrected many issues involving steering, ride quality, and performance by redesigning the
suspension. This year the team will keep the same suspension design and focus efforts on weight
reduction. The desired weight reduction of 100 pounds can be achieved through applying
principles of Finite Element Analysis (FEA) and material selection. Previous frame designs have
been overbuilt with material that was too thick, or supported with unnecessary members adding
extra weight. Each sub-system will be redesigned using FEA software to minimize the weight,
and retain the structural integrity. 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.
III. Non-Disclosure Statement
The information provided in or for this proposal is the confidential, proprietary property of the
Saluki Engineering Company of Carbondale, Illinois, USA. Such information may be used
solely by the party to whom this proposal has been submitted by Saluki Engineering Company
and solely for the purpose of evaluating this proposal. The submittal of this proposal confers no
right in, or license to use, or right to disclose to others for any purpose, the subject matter, or
such information and data, nor confers the right to reproduce, or offer such information for sale.
All drawings, specifications, and other writings supplied with this proposal are to be returned to
Saluki Engineering Company promptly upon request. The use of this information, other than for
the purpose of evaluating this proposal, is subject to the terms of an agreement under which
services are to be performed pursuant to this proposal.
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F13-60-Baja
IV. Table of Contents
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
Cover Page
Executive Summary
Non-Disclosure Statement
Table of Contents
Figure List
Introduction
Literature Review
A. SAE Saluki Background
B. Frame Design
i.
Frame Design Overview
ii.
General Baja Car Specification
iii.
Problem Statement of Frame Design
iv.
Solution
v.
Triangulation
C. Material Selection
D. Finite Element Analysis
Basis of Design
Project Description
E. Block Diagram
Scope of Work
F. Design Activities List
G. Deliverables
H. Sub-system descriptions
i. Material Selection
ii. Frame Design
iii. FEA
Price Section
Validity Statement
Management Section
I. Timeline
J. AIL
References
Appendix
5
1-2
4
4
5
6
7
7
7
7
8
9
10
10
10
10
11
13
14
14
15
15
15
15
15
17
19
21
21
22
23
24
25
27
F13-60-Baja
V. Figure List
Figure I: Young’s Modulus vs. Density Material Selection Chart [Ref#11]-p.16
Figure II: Drawing of Roll-Hoop for Frame-p.18
Figure III: Front-end Drawing with Dimensions for Frame-p.19
Figure IV: Example of FEA applied to a Baja car’s Frame [Ref#4]-p.20
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F13-60-Baja
VI. Introduction
Baja vehicles are built for the purpose of mass production for sale to the general public as
a recreational vehicle. With this being said the vehicles must be very durable, and hold safety
paramount. The way these requirements are met resides in the design and construction. Baja
vehicles are built from the ground up in the form of a tube frame chassis. These chassis are often
the heaviest of all components on the car. The main goal of this project is to reduce the weight of
the vehicle. One of the ways that weight can be reduced is by addressing the frame. Last year the
team focused heavily on designing a more responsive suspension system with better
performance. This focus on the suspension lead to a neglect in terms of frame design. The frame
was far overbuilt, and in turn holds much of the excess weight. These goals of weight reduction
can be accomplished by applying principles of FEA, material selection, and designing rather than
fabricating the frame.
VII. Literature Review
A. SAE Saluki Baja Background
As previously stated, last year’s Baja team designed the suspension and steering
components. The frame and other subsystems were simply fabricated around this design. This
resulted in many excess frame members being put in place, and almost all of the bracing being
far overbuilt. This resulted in a great durability; however it came at the price of weight. The car
tips the scales at 525 pounds. To be competitive against top 5 teams in the SAE competition
series, the car needs to shed at least 200 pounds while maintaining the current handling and
durability characteristics. At competition this year, the vehicles handling and suspension allowed
for a top ten start and defending its position for the first two laps. After all the lighter weight cars
had weaved through the pack, the low top-end speed of the car allowed other teams to easily pass
on open sections of the course. After evaluation of last year’s design, an attainable goal of
reducing 100 pounds off the current vehicle has been set for this year. Methods of FEA and
material selection will drive the accomplishment of this milestone. Once the frame is modeled
using CAD software, static and dynamic FEA testing of the new frame will be performed using
Autodesk Inventor.
B. Frame Design [KL] [SB] [TT]
The frame of any vehicle in its most basic form is an interior skeleton. This skeleton must
be strong enough to protect the driver from any potential harm. A 2014 Baja SAE rule states that
there must be a lateral spacing of 6-inch clearance around the driver’s helmet and a 3-inch
clearance around the driver’s shoulders, torso, hips, thighs, knees, arms, elbows, and hands.
Another rule is that for the elements of the roll cage which consist of primary members of the
Rear Roll Hoop (RRH), Roll Hoop Overhead Members (RHO), Front Bracing Members (FBM),
Lateral Cross Member (LC), and Front Lateral Cross Member (FLC) be made of tubular steel.
The tubular steel must have a “bending stiffness and bending strength exceeding that of circular
steel tubing with an outside diameter of 1-inch and a wall thickness of 0.120-inch and a carbon
content of 0.18%. The wall thickness must be at least 0.062-inch, regardless of material or
section size” [1, p26]. Secondary members which consist of Lateral Diagonal Bracing (LBD),
Lower Frame Side (LFS), Side Impact Member (SIM), Fore/Aft Bracing (FAB), Under Seat
7
F13-60-Baja
Member (USM), any tube that is used to mount the safety belts, and all other required Cross
Members must have a minimum wall thickness of 0.035-inch and a minimum outside diameter
of 1-inch. Also the roll cage members that are bent must not exceed 28 inches between supports
on the straight sections [1].
A frame may be constructed from many different materials. Some larger vehicles are
made of square tubing. Although square tubing is stronger in members that are at angles, it has
more short-comings in the application of building a SAE Baja. Square tubing will kink because
the excess material in the corners. This means all of the square tubing must contain mitered
angles and then be welded to make one solid piece. Round tubing can easily be bent and to a
much greater angle with only minimal kinking. Since, square tubing uses more material than the
standard round tubing, the overall weight of the car increases and the price is higher. The goal of
the project is to build a light weight frame, hence, the round tube would be preferred for both
weight and economic reasons.
i.
Frame Design Overview [TT] [SB] [KL]
To develop a preliminary design, the design guidelines should be set first. The design
guidelines will include not only design features, but also the limitations of tools used during the
fabrication process. The suspension and steering design as well as intended fabrication methods
must be taken into account. Rules referring to frame geometry and safety of the driver must be
considered as well. The design process begins with the selection of major components such as
the overall dimension, ride height, wheels, suspension geometry, and drivetrain [2]. The most
common design for a Baja vehicle frame is a tubular space frame which has a series of tubes
connected in different ways to form a support structure [3]. An efficient frame must be stiff
enough to handle the loads and light enough to deliver good performance.
Research has shown that for loads higher than 9 times the force of gravity or 9 G’s, the
human body will lose consciousness. Therefore, 10 G’s is an extreme worst-case collision [3].
By calculation, a value of 10 G’s is equal to a static force of 26,698 N or 6,000 lbf load on the
vehicle. The estimated maximum g-force that a SAE Baja will experience is 7.9 G [4].
Therefore, the designed frame must protect and keep a driver alive during a 7.9 G front, 7.9 G
side impact and 7.9 G roll over situation.
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F13-60-Baja
ii.
General Baja Car Specification [TT]
Given the past data from table I of various Baja vehicles that typically do well in all
events are similar in most aspects.
Table I [5]
General Dimensions of Various Baja Submissions
University
SIU
SIU-C
IPU-FW
IPU-FW
UT-C
UW-P
BYU-I
BYU-I
AVG
Year of Submission
2013
2012
2008
2007
2006
2009
2005
2004
NA
Competition
Midwest
Midwest
Midwest
Midwest
Midwest
Midwest
West
West
NA
Empty Weight
550
597
472
NA
430
NA
NA
NA
512
Weight w/ Driver
NA
700
NA
NA
600
500
NA
NA
600
Overall Length
86
93
88
92
92.5
NA
NA
NA
90.3
Maximum Width
54
52
53
62
54
NA
NA
NA
55
Wheel Track
NA
NA
NA
NA
48.5
56
NA
NA
52.25
Static Ride Height -Front
12
10.5
12
12
10
12
11.5
8
11
Travel - Front
10
8
7
7
10
NA
10
5
8.14
Static Ride Height -Rear
12
10.5
12
12
10
12
14
10
11.56
Travel - Rear
12
7
3.5
7
8
NA
12
8
8.2
Weight Distribution
40:60
36:64
36:64
NA
40:60
NA
NA
NA
38:62
iii.
Problem Statement of Frame Design [TT]
There are two main types of stiffness in vehicle frame design: bending and torsional
stiffness. Bending is not a concern for a Baja frame because midpoint bending does not affect
suspension performance [2]. Torsional stiffness has resistance in the frame to twisting loads [2].
Any misalignments in the suspension geometry can create moments within the frame structure
that could cause catastrophic failure of the frame, resulting in driver injury [2].
iv.
Solution [TT] [SB]
To increase torsional stiffness, two methods have been used by many Baja teams. One
method is to increase the amount of material to the frame structure, which means increasing the
total weight of the frame. Hence, the overall performance of the car would decrease. The other
method to increase torsional stiffness is triangulation, which is the more efficient technique. In
this method, several frame members are connected and combined to form triangles. This
technique will significantly strengthen the frame without adding unnecessary weight and will be
used in this project [2].
9
F13-60-Baja
v.
Triangulation [TT] [SB]
Nodes can be made significantly stronger by using the triangulation, a method capable of
handling large forces. Because these nodes can accommodate large loads, they are an excellent
location to mount the suspension points. In addition, triangulation creates a clear load path within
the chassis. With a coherent load path in a structure, forces are distributed evenly over the many
interconnected members. Thus triangulation reduces the force and stress felt by any individual
member. In contrast, without a coherent load path, the structure will fail due to the load being
concentrated on one element [2].
To reduce the weight of the frame, thin walled tubes may be used. These tubes perform
greatly in compression and tension; however, they do not perform well in bending. In order to
help prevent the members from bending, the frame should be constructed from multiple shorter
members [2].
C. Material Selection [PM]
Some teams that compete at a SAE Baja sanctioned event use 1018 steel for a major part of
their vehicles frame fabrication. Typically, 1018 is the most readily available cold-rolled steel
and is durable. The carbon content is quite low, at only 0.15 to 0.2 percent, the phosphorous
content of 0.04 percent maximum and sulfur content of 0.05 percent maximum are low enough
that they have little impact on the material's physical properties. Like other, more complex steels,
1018 contains trace elements such as chromium, tungsten and silicon, which give tool steels
added corrosion resistance and toughness [6]. The lack of a moderate chromium content and
simple chemistry, however, make 1018 prone to oxidation, necessitating an air-tight coating to
protect the steel from rusting too quickly [7].
The most commonly used steel for frame design is 4130, also known as Chromoly. The 4130
consist of two main alloying materials: chromium and molybdenum with a carbon content of
0.3%. Chromoly is widely used in aircrafts, bicycles, and drag race vehicles for its strength,
toughness, and ductility. It has great strength to weight ratio as well as excellent heat treating
properties. With a 100,000 psi normal tensile strength, this steel is ideal for off-road applications.
Its alloying also makes it considerably more rust resistant. The 4130 is available in two subsets:
4130A (annealed) and 4130N (normalized). Annealed indicates the softest form and means it can
be easily formed [6]. Normalized means the material is in its neutral, non-heat treated form. Its
nominal hardness gives 4130N a far greater strength than 4130A [7].
10
F13-60-Baja
Table II is a side-by-side comparison of the 1018 steel and 4130(N) steel. Clearly the 4130(N)
meets or exceeds in all aspects necessary for an off-road vehicle.
Material Comparison [PM]
Table II
Comparison of 4130(N) & 1018
4130(N) vs. 1018
4130(N)
1018
Density (g/cm3)
7.8
7.8
% Elongation at Break
26
15
Hardness Brinell
197
126
Strength to Weight Ratio Tensile, Ultimate (kN-m/kg)
85
56
Strength to Weight Ratio Tensile, Yield (kN-m/kg)
55
47
Tensile Strength Ultimate (MPa)
670
440
Tensile Strength: Yield (proof) (MPa)
435
370
D. Finite Element Analysis [AL] [KK]
Strategy of Finite Element Analysis [KK] [AL]
Since the mid 1960’s, Finite Element Analysis (FEA) has been a useful tool used to solve
problems concerning chassis and frame design. FEA is a computerized process that enables
engineers to place calculated loads at certain “nodes,” or points of interest where a load would be
concentrated in the real world. Advantages of using FEA include improving safety, durability,
reducing material waste, and most importantly weight reduction [8].
Calculating Forces [KK]
For safety reasons, it is important to calculate the limits of any product. It is also
imperative to incorporate a safety factor, which ensures a certain material will not fail even if
forces to a certain percentage above calculated limits are applied to a prototype [9]. When
designing a frame, primary calculations that need to be completed include area, force, angles,
acceleration, torque, stress, strain, and strength. Several of these calculations may be computed
through the FEA program itself, while some are found independently of the program.
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F13-60-Baja
Force Application Points [KK]
The ability to apply simulated forces to a frame and to view the reactions of every
member within a frame proves to be extremely critical in frame design. However, an individual
must still be knowledgeable on force position and calculation. The joints supporting the wheels
and suspension are important because these particular joints receive the most impacts. More than
four actual joints are associated with the linking of the wheels and suspension to the frame, but
each individual joint is equally important. Other essential force application points on a frame
include front, side, rear, top, and even bottom impact forces. These particular impact forces are
the most important when considering the safety of the operator. A favorable frame design will
come from the proper load placement, calculation, and utilization of FEA to optimize the weight,
durability and, of course, the safety of the vehicle.
The FEA Standard [KK] [AL]
Structural optimization is the purpose of FEA in regards to SAE Baja. The goals of
applying the FEA process include producing more lightweight, durable, and efficient vehicles.
The program calculates if a member’s length or wall thickness can be downsized without
compromising the integrity. One strategy used by the Baja team at the University of Florida is an
iterative method consisting of tracking the stress throughout the frame over a period of 0.25
seconds. The team used Chromoly tubing 1" in diameter with a wall thickness of 0.065.” The
member at this size left the Von Mises stress to be too high in regards to the desired safety
factor; thus the size of the member was increased to further reduce the stress at that node. This
process was repeated until a suitable size member that would absorb the loading at that point in
time was found [4].
A set of transient impact tests are held as the standard for producing safe vehicles for the
general public. The tests include frontal, rear, and side impacts. For each of these situations
there are standards of the crash procedure. For example, the velocity of a frontal and side impacts
are evaluated at 40 mph and 30 mph, respectively [4]. Although these tests do cover many daily
driver incidents, they do not cover the typical roll over events seen in the SAE Baja
competitions. This area of impact to the top of a roll cage has been neglected because many
passenger cars rarely see this type of incident.
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F13-60-Baja
Analyzing FEA Results [KK] [AL]
FEA simply performs the advanced calculation of forces and stresses at different points
in a frame. When a node’s load exceeds its stress handling capabilities, the designer must be able
to adjust the design in the most efficient way possible. When considering the SAE Baja vehicle’s
frame, the most likely option for correcting an error is to add or move a support member to
lessen the stress on the overloaded node. After one member or node is adjusted, the simulation is
repeated, and the iterative process continues [4]. The Federal University of Minas Gerais,
conducted a modal vibration analysis of a tubular structure vehicle. From testing six modes of
vibration, including torsional loading and drivetrain vibration, the following conclusions are
reached [10]:

Triangulating chassis regions with braced members improves overall frame stiffness

Square cross section members applied to lower spars can improve fore roll cage stiffness

Vibrations from the engine operating at low speeds will excite the frame vibration mode

Severe torsional loads applied to fore and aft sections of frame can cause suspension
misalignment, and can be fixed with cross bracing.
VIII. Basis of Design
The documents associated with the basis of design work to be followed by F13-60-BAJA
can be found in the list table below:
Document
Request for Proposal (RFP)
SAE Baja Rule Book
Block Diagram
Project Specification
Proposal for Project
Date
10-Sep-13
11-Sep-13
8-Oct-13
8-Oct-13
21-Nov-13
13
F13-60-Baja
IX. Project Description
This project will be divided into the following subsystems:





Front End
Cockpit
Rear End
Finite Element Analysis
Material Selection
All of these subsystems are highly dependent on each other, and through excellence in project
coordination, fabrication, and testing, the goals of weight reduction while maintaining the
suspension geometry, and other parameters displayed in table can be attained. When all goals are
reached, the vehicle will exceed anything SIU has ever produced, and be a top contender in
national competition.
E. Block Diagram
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F13-60-Baja
X. Scope of Work
F. Design activities list
o Design frame using Autodesk Inventor that meets safety and geometric
constraints of SAE
o Perform FEA on all subsystem components including
 Front end
 Cockpit
 Rear end
 Suspension mount points
 Control system mount points
o Fabrication of parts
o Assembly of all subsystems
o Perform testing before competition
o Implement optimal frame design, and compete in 2014 SAE Baja Competition
G. Deliverables
o
o
o
o
o
Cad renderings of all sub system assemblies
FEA of frame
Validations to all design changes to be implemented
Testing to show design outcomes
Implementation on 2014 SAE Saluki Baja vehicle
H. Sub-system descriptions
i.
Material Selection:
Material selection is the first step of the design process. The purpose of material
selection is to evaluate candidate materials in order to achieve the best combination of price,
safety, and performance of the design. Candidate materials are scanned through product analysis
to figure out the best application. In this particular case, the frame is analyzed based on what it
can do. How does it do it? Where does it do it? Who uses it? And what should it cost?
The Baja car’s frame is used by SAE members and students in off-road racing. It functions as
an interior skeleton to protect the driver and support other sub-systems on the vehicle. It is
expected to cost around $900.
Materials may be selected by using material selection charts. Aluminum and steel have
been found to be two popular materials used in Baja frame designs.
15
F13-60-Baja
Figure I [11]
Young’s Modulus – Density Materials Selection Chart
Based on the materials selection chart, aluminum alloys are less stiff than steel, but they
are lighter. However, by SAE rules for the 2014 season, only steel tubing of at least 0.18%
carbon content can be used for the primary roll cage. The material chosen to construct the frame
must meet certain safety specifications according to the 2014 SAE Rulebook. These rules state
that the primary roll cage “must be steel tubing with an outside diameter of 1 inch and a wall
thickness of 0.120 inch and a carbon content of at least 0.18%,” or a greater bending stiffness
and bending strength of circular steel tubing [1].
16
F13-60-Baja
Table III: [12, 13]
Steel Alloy
AISI
1018
1030
1040
1050
1060
1095
4130
4140
4340
Yield Strength
MPA
310
345
374
427
421
500
436
655
855
Tensile Strength, Density
Hardness
3
Ultimate (Mpa)
Kg/m
g/cc
USD/Ton
450
7.87
73
700
525
7.8
80
1500
595
7.845
86
1200
752
7.87
95
900
772
7.852
96
2000
1015
7.85
99
4500
670
7.85
92
1500
1020
7.85
99
1600
1282
7.85
100
1800
Based on the table of Steel alloys, AISI 1095, 4130, 4140, 4340 are critical candidate
materials for the production of an off-road vehicle. All of them have high strength to weight
ratios. The 4130 is used because it is the most cost efficient of these alloys.
Properties of the chosen material guide engineers in which method of design to follow,
and how to fabricate of the frame. For instance, AISI 4130 is a low alloy steel which contains
molybdenum and chromium as strengthening agents. With low carbon content of 0.3%, 4130
alloy is an excellent option, and it can be easily welded which is also crucial [14]. This welding
property and other properties of 4130 make this alloy one of the most attractive options to use for
the frame. However, the chosen material will still have certain limitations that the design team
will have to consider.
ii.
Frame Design
The SAE Saluki Baja team designed a frame that focused on safety, durability,
manufacturability, and weight. A SAE Baja frame includes roll cage, front end, and rear end.
These elements are designed based on the chosen material which is AISI 4030 in the material
selection. The team created a 3-D model of the frame by using Autodesk Inventor Professional
software. The 3-D model provided the team an image on how the frame was going to look like.
In addition, the 3-D model help the team know exact dimensions for frame members. With
setting parameters such as material properties, section properties, constraints, loading conditions,
and other parameters for setting simulation, a computer software was used for FEA to make a
static analysis on the frame. Using the results of FEA to modify the frame. Manufacturing and
cost issues were considered to improve a final design.
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F13-60-Baja
Roll Cage (Cockpit)
The following are the primary members of the roll cage:





Rear Roll Hoop (RRH)
Roll Hoop Overhead Members (RHO)
Front Bracing Members (FBM)
Lateral Cross Member (LC)
Front Lateral Cross Member (FLC)
The following are the secondary members of the roll cage:





Lateral Diagonal Bracing (LDB)
Lower Frame Side (LFS)
Side Impact Member (SIM)
Fore/Aft Bracing (FAB)
Under Seat Member (USM)
The roll cage is the
main part of the vehicle
that all other
components are built
off of. The purpose of
the cockpit is to protect
the driver and allow the
driver to easily exit in
case of an emergency.
There are many
guidelines that must be
followed according to
the 2014 SAE Baja
Rule Book. Some of
which require a certain
distance between any
member and the helmet
Figure II: Drawing of frame with engine, CVT, and gear box.
of the driver, thickness of
certain members, and bracing
on members. As long as the rules are met, there are countless options that could be chosen. But
we would like to keep our car as small and light as possible. We have shortened the overall
length of our car 6 inches, the height 1 inch, and the width 1 inch while keeping the same
suspension geometry from last year. All of this has been done while maintaining the proper level
of safety that is necessary.
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F13-60-Baja
Front End
The front end is
attached to the front of
the roll cage. The
purpose of the front end
is to connect the
steering, suspension, and
breaking systems to the
rest of the car. We have
been able to maintain all
the necessary subsystems
and keep the strength up,
while shortening the
length on the front end.
The purpose of making the front
Figure III: Drawing of front-end with dimensions.
end as short as possible is
because it will cut out
unnecessary weight and allow us to have a better center of gravity. We will be performing the
necessary tests to design the front end using the lightest material possible that can withstand the
maximum forces that will be exerted upon it.
Rear End
The rear end of the vehicle is attached behind the cockpit. The rear end holds the impacts
from the rear suspension, as well as all the loads from the engine and transmission. We are
shortening the rear end by bringing our engine and transmission closer to the body. This gets rid
of as much unnecessary empty space as possible. By doing this, it will again help with shedding
weight and making our center of gravity more compact.
iii.
Finite Element Analysis
Finite Element Analysis (FEA) is usually the last step in the design process. However, if
the results of FEA on a frame design are not desirable, an engineer is usually cycled back to
correct the flaws of the original design. This cycle may be repeated many times until a
satisfactory frame is developed. FEA of a poorly designed frame will display every significant
flaw with color-coordinated drawings produced on a computer program such as AutoDesk
Inventor Professional. FEA will be used by the 2013-2014 SAE Saluki Baja Team in order to
analyze critical failure points, increase quality of design, and to ensure safety.
Critical failure points will be analyzed on the original frame produced by the design team
using FEA. Once these points are located, our design team plans to correct errors by introducing
support beams and braces to avoid frame failure. A frame is an enclosed system of supports and
beams, and if one point fails, the results would be serious risk of danger. The FEA will also be
used to accomplish our biggest goal for the year, which is to reduce the weight of the frame.
19
F13-60-Baja
A quality design can only be accomplished when the safety, performance, and cost are
combined to meet the demanded requirements in the most efficient manner possible. Our most
important goal, as stated, is to increase performance of the Baja car’s frame. Using multiple
iterations of FEA on our frame designs will allow our team to minimize the amount of
Chromoly-4130 tubing needed in the frame by maximizing the support placements, and to
remove supports that are unnecessary. FEA
will allow our frame to perform to our
requirement while using the least amount of
material. Using the smallest amount of tubing
possible will maximize our cars performance
by reducing weight and increasing speed, but
we will have to ensure that safety requirements
are still met.
Safety is the most important factor to
consider for an engineer that is designing a
product for the public. Engineering ethics state
that the safety of the public should be
considered above all other options, such as
money or self-promotion. The object of the
SAE Baja competition is to design a costefficient vehicle that can be mass-produced
Figure IV: FEA results of safe Baja car frame [Ref#4]
while maintaining a desired level of safety.
Although our car will not actually be sold to
the public, our design could potentially be used according to the format of the SAE Baja design
competition. FEA will also help our team meet safety requirements. It shows where safety is of
significant concern by calculating stresses with a given input forces that must be calculated for
extreme conditions such as head on, side, and rear impacts. Input forces are also applied to the
roll-cage which is on the top portion of the frame, and this would simulate a roll-over of the car.
Equations at their basic form to be used for calculations include the following:
1. 𝐹 = 𝑚𝑎
2. 𝑎 = 𝑑𝑣 ⁄𝑑𝑡
3. 𝐹 =
4. 𝐹 =
(1⁄2)𝑚𝑣 2
𝑑
𝑚𝑔ℎ
𝑑
The frame pictured in figure IV is an example of a safe design as all of the stresses are well
below the specified materials failure point. If there were critical locations that needed to be
addressed, they would appear dark red rather than all blue with some green. The specific material
selected must be input to FEA so the program can consider the strength of the material used, and
provide feedback as to whether or not the frame will be at risk of breaking under the given load.
Failure of the frame would likely result in significant harm to the operator, and so failure of the
frame must be avoided at all cost.
20
F13-60-Baja
XI. Price Section
Table IV: Pricing and Resources Required
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
Location
Sub
Total
Location
$3.19 $127.60
$3.27 $98.10
$3.44 $68.80
$3.89 $155.60
$3.19
$31.90
$3.22
$32.20
$514.20
Mounting Tabs
.125"x12"x12" Chromoly Sheet
.032"x48"x120" Aluminum Sheet
5
1
$39.46 $197.30
$143.14 $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
2
1
1
1
1
1
1
1
4
6
2
1
1
1
1
Total
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
XII. Validity Statement
This proposal is valid for a period of 30 days from the date of the proposal. After this
time, Saluki Engineering Company reserves the right to review it and determine if any
modification is needed.
21
F13-60-Baja
XIII. Management Section
I. AIL
Task Name
Duration
Phase 2 Work
RRH Jig
Cut/Bend/Cope/Weld RRH
2 days
7 days
BF Jig
2 days
Cut/Bend/Cope/Weld base frame
Front End Jigs
5 days
2 days
Cut/Bend/Cope/Weld front end
5 days
Rear End Jigs
Cut/Bend/Cope/Weld rear end
Cockpit Support Jigs
Cut/Bend/Cope/Weld Cockpit
overhead and support members
3 days
9 days
3 days
4 days
Start
Mon 1/6/14
Tue 1/7/14
Mon
1/13/14
Tue 1/14/14
Fri 1/24/14
Mon
1/27/14
Mon 2/3/14
Thu 2/6/14
Thu 2/6/14
Mon
2/17/14
22
Finish
%
Complete
Resource
Names
0%
Tue 1/7/14 0%
Wed 1/15/14 0%
Preston
Steven
Tue 1/14/14 0%
Thang
Mon 1/20/14 0%
Mon 1/27/14 0%
Austin
Austin
Fri 1/31/14
0%
Keegan
Wed 2/5/14 0%
Tue 2/18/14 0%
Mon 2/10/14 0%
Kyle
Keegan
Austin
Thu 2/20/14 0%
Preston
F13-60-Baja
Finish weld all frame members
2 days
Mount engine and transmission
Mount seat/safety harness mounts
Cut/Bend/Cope/Weld front A-arm
uppers
Cut/Bend/Cope/Weld front A-arm
lowers
Cut/Bend/Cope/Weld trailing arms
Machine Knuckles
Machine spindles
Mount front suspension
Mount rear suspension
Design shifter mounts
Fabricate shifter subassembly
Design brake control subsystem
Fabricate brake control mount
subsystem
Run brake lines/assemble brake
subsystem
Design accelerator control subsystem
Fabricate accelerator control
subsystem
Fabricate steering subsystem
Assemble wiring harness
Phase 3 Work
Fri 2/28/14 Mon 3/3/14
0%
0%
0%
Keegan
Steven
Kyle
0%
Austin
0%
Austin
0%
0%
0%
0%
0%
0%
0%
0%
Preston
Shop members
Shop members
Shop members
Shop members
Kyle
Steven
Thang
0%
Thang
0%
Shop members
0%
Preston
0%
Preston
0%
0%
0%
Keegan
Shop members
0%
Shop
members,Tea
m
Shop
members,Tea
m
Shop members
0%
Shop members
Testing/Modifying Suspension settings
0%
Testing/Modifying functionality of
control systems
0%
Disassemble and prepare for paint
Paint: Frame/Suspension/Control
systems
Final assembly of car
Competition cost report due
Competiton design report due
Complete the 2013-2014 SAE Saluki
Baja
Test the 2013-2014 SAE Saluki Baja
Compete in 2014 Baja SAE Kansas
National Competition
Tue 3/4/14
Tue 4/1/14
Fri 3/7/14
Wed 4/16/14
0%
0%
0%
Team
4 days
12 days
91 days
Fri 11/1/13
Fri 3/7/14
0%
Team
54 days
Mon 3/17/14 Thu 5/29/14
0%
Team
3 days
Thu 5/22/14 Sun 5/25/14
0%
Team
23
F13-60-Baja
J. Timeline
24
F13-60-Baja
XIV. References
[1] SAE. 2014 Baja SAE Series Rules. SAE International 2014. 12 Sept. 2013.
<http://www.sae.org/students/2014_baja_rules_8-2103.pdf>
[2] Gaffney III, Edmund, and Anthony Salinas. "Introduction to Formula SAE Suspension and
Frame Design”. University of Missouri, Rolla, 971584.
[3] N. Noorbhasha, “Computational analysis for improved design of an SAE BAJA frame
structure,” University of Nevada, Las Vegas., Las Vegas, 736, Dec. 2010. Available:
http://digitalscholarship.unlv.edu/cgi/viewcontent.cgi?article=1737&context=thesesdissertations
[4] Mini Baja Florida Tech, “Chassis” Florida Institute of Technology, pp. 30-45. 2008.
Available: http://forums.bajasae.net/forum/uploads/130/FL_TECH_FRAME.pdf
[5] B. Probst et al., “SAE Baja Suspension Literature Review”, SEC., Carbondale., IL, Tech, Oct
2012.
[6] C. Shelton, “The Steel Age,” DIRTsports, Issue 9, p35-40, 6p. Sept. 2005.
[7] A. M. Soo, “Design, Manufacturing, and Verification of a Steel Tube Space frame Chassis
for Formula SAE,” Dep. Of Mech. Engr., Massachusetts Institute of Technology, Cambridge,
Jun. 2008.
[8] J. Pemegger. (1997, December 22). Finite Element Analysis of Bolted Flange Connections.
[Online]. Available: http://www.hydrocarbononline.com/doc/finite-element-analysis-of-boltedflange-conn-0001?VNETCOOKIE=NO
25
F13-60-Baja
[9] A. Purushatham. (2013, May 5). Static Stress and Deflection Analysis of a Three-wheeler
Chassis. [Journal]. Available: http://web.ebscohost.com/ehost/detail?vid=2&sid=b0e20a6a-e67341fa-9943cd8ce4208798%40sessionmgr104&hid=118&bdata=JnNpdGU9ZWhvc3QtbGl2ZSZzY29wZT1
zaXRl#db=ofs&AN=89631145
[10] Frederico Mol Alvares da Silva, “Modal Analysis of a Tubular Structure Vehicle Chassis”
Federal University of Minas Gerais – UFMG 2004-01-3423
[11]: “Introduction to Material Selection Charts: Mechanical Properties in Physics, and Design.”
Internet: http://www-materials.eng.cam.ac.uk/mpsite/physics/introduction/, Feb. 25, 2002 [Nov.
5, 2013]
[12]: “MatWeb, Material Property Data.” Internet: http://www.matweb.com/index.aspx,
[Nov. 5, 2013]
[13]: “Alloy Steel Price Per Ton.” Internet: http://www.alibaba.com/showroom/alloy-steel-priceper-ton.html, [Nov. 5, 2013]
[14]: “4130 Alloy Steels Material Property Data Sheet.” Internet: http://www.supplieronline.com
/propetypages/4130.asp, [Nov. 5, 2013]
26
F13-60-Baja
Austin Lewandowski
309.370.9774
Austin27ski@gmail.com
440 E Town Hall Rd
Metamora IL, 61548
500 West Freeman, Apt 5
Carbondale, IL 62901
OBJECTIVE: To obtain a job at Advanced Technology Services, where I can apply my technical
engineering, project management, and leadership skills.
EDUCATION:
Southern Illinois University, Carbondale IL, 62901
Bachelor of Science in Mechanical Engineering, May 2014
GPA:
3.8/4.0
Illinois Central College, East Peoria, IL 61612
GPA: 3.98/4.0
Associates of Arts and Science Degree, Summer 2012
Senior Design Project: SAE Baja Frame Design
Performing FEA analysis, and applying material selection principles on 2014 SAE competition Baja car
to find weak points in current design. This will also allow the overall weight, durability, and cost of the
car to be optimized.
Relevant Coursework:
 Machine Design
 Controls




Cad/Cam/FEA
Thermodynamics 1/2
Material Selection
Internal Combustion
EXPERIENCE:
Advanced Technology Services Internship:

May 2013- August 2013
Participated in two Six Sigma projects with savings totaling $115,000 and generating up to
$200,000 in additional revenue while working at Caterpillar, Inc.
Baja SAE:



August 2012-Present
Provide leadership as Vice President to a team placing 56th out of 108 teams
Machined, welded, fabricated control systems for the vehicle.
Performed design/FEA analysis in Inventor on subsystems of the car.
Leadership Development Program – SIU College of Engineering
Present


:
August 2012-
Managed team of 16 SIU students in a 4 day 5S event for Caterpillar, Inc.
SEMO Food bank, Missouri River clean up, Shawnee National Forest trail maintenance projects
Honors/Awards:



Awarded $20,000 in scholarships since fall 2011, based on academics and leadership activities.
Leadership Development Program Scholarship 2012, 2013
Dean’s List 2013, 2012
Computer Skills:
Inventor/Pro E
Matlab/Simulink
27
Microsoft Office
F13-60-Baja
Kyle R. Koester
kylkoester@siu.edu
16139 E. 1485th Ave – Teutopolis, IL. 62467 – 217-690-0880
EDUCATION
Southern Illinois University of Carbondale
Bachelors of Science, Mechanical Engineering
Current SIU-C GPA: 3.2/4.0
Carbondale, IL
May 2014
Lake Land College
Associates of Science, Pre-Engineering Program
Transfer GPA: 3.4/ 4.0
Mattoon, IL
May 2012
EMPLOYMENT
IHI Turbo America
Shelbyville, IL
Engineering Intern
Summer 2013
 Operated industrial machines, presses, saws, mills, and lathes
 Reviewed product and manufacturing engineering drawings
 Assisted in testing and improving product durability
 Assisted with assembly and disassembly of superchargers and turbochargers
 Created data spreadsheets for inventory and measurements
K & W Auto Electric
Teutopolis, IL
Automotive Starter and Alternator Technician
March 2008 -January 2013
 Operated various industrial machines, presses, saws, and lathes
 Tested starters, alternators, and batteries for automobiles and other machinery
 Remanufactured automotive, construction, and agricultural starters and alternators
SKILLS
Technical Skills: Experience with small appliance repair, many industrial machines,
knowledge for assembling and testing automotive electrical equipment
Computer Skills:




Microsoft Office
SolidWorks
C-Programming
MATLAB
INVOLVEMENT
 Member of SAE Saluki Baja Senior Design Team
Fall 2013-Spring 2014
HONORS
 Inducted into National Honor Society at Teutopolis High School
Fall 2008
 BOOST (Building Occupational Opportunities for Students in Technology)
Scholarship
Fall 2010, 2011
28
F13-60-Baja
THANG QUANG TRAN
sstqtssstudy@siu.edu
Permanent Address:
College Address:
University Apartments, Apt. 25
510 S. University Avenue
Carbondale, IL 62901
Cell: (403) 255-0147
Southern Illinois University
1230 Lincoln Drive
Carbondale, IL 62901
Objective
Applying for an excellent opportunity to work as mechanical engineering with my engineering
experiences and background.
Education
Southern Illinois University-Carbondale
B.S. Degree in Mechanical Engineering
GPA: 3.946/4.0
Relevant Coursework
 Calculus I, II & III
 Material in Energy
 Numerical Method
 Mechanical Analysis & Design
Carbondale, Illinois
Expected Graduation: Summer 2014




Linguistics I&II
Mathematics in Engineering
Thermodynamics I&II
Mechanical Engineering Controls
Experience
Skills:





Having practical knowledge of basic engineering
Good communication and organization skills
Having experience with working in groups or teams
Able to work independently and under pressure
Vietnamese as the first language
Computer Skills:



Having computer experience with Microsoft Word, Excel and Power Point
Some use of Auto CAD and Visual basic
Some use of MatLab
Awards and Honors



SIUC Dean’s List 2010, 2011, 2012, and 2013
SIUC Academic Honors 2013
Delyte W. Morris Scholarship 2013
Activities


Member: Tau Beta Pi, 2011
29
Member: SAE Saluki Baja, 2013
F13-60-Baja
Preston Foiles Mathis
510 South University Avenue
Apartment 39
Carbondale, IL 62901
(217)-710-0368
pmathis@siu.edu
Objective: Seeking an internship opportunity as a mechanical engineer with a reputed company in
heavy/agricultural equipment.
Skills:







Military experience
Excellent communication and organizational skills
Proficient at establishing teamwork
Excellent adaptation to working under pressure
Strong leader
Raised in an agrarian environment
Experienced with Microsoft Excel, Word, Auto CAD, Solid Works
Previous Work Experience
Heavy Equipment Operator with Precision Applied Coatings, Cahokia, Illinois.
( April 20 2009 – April 20 2010)
Responsibilities include
 Responsible for the movement and logistics of structural steel
 Enforced emphasis on safe working environment for other employees
 Competed other duties as assigned
Aviation Boatwains Mate (Fuels) 3rd Class with United States Navy, onboard USS Harry S Truman
CVN-75, Norfolk, Virginia.
(June 15 2005 - April 15 2009)
Responsibilities include
 Responsible for the integrity and productivity of JP-5 fuel systems
 Oversaw proper conduct and regulation of the aviation fuels operational sequencing system
(AFOSS)
 Insured the production of providing clean, clear, and bright aviation fuel to the flight deck
 Operator of the JP-5 fuel console, filters, and pump room systems.
 Responsible for watch standing and security roving of fuel systems for imperfections
 Physical training coordinator for V-4 fuels division.
 Individual Augmentee Volunteer – temporary transfer to perform duties in Jalalabad, Afghanistan
in coherence with Operation Enduring Freedom.
Education
 Bachelors of Science (Mechanical Engineering) from Southern Illinois University, Carbondale,
Illinois
GPA 3.0/4.0
 Associates of Science from Lewis and Clark Community College, Godfrey, Illinois
GPA 3.5/4.0

Military education – Aviation Boatwains Mate (Fuels) A-school, Naval Air Technical
Training Center Pensacola, Florida
30
F13-60-Baja
Steven Baldwin
703 W Pecan Street
Carbondale, IL 62901
(309) 712-6515
steven.baldwin09@siu.edu
EDUCATION
Southern Illinois University, Carbondale, IL
Bachelor of Science in Mechanical Engineering
Minor in Mathematics
Expected Graduation Date: May 2014
GPA: 2.97/4.0
Illinois Central College, East Peoria, IL
Associate of Science
Graduation Date: July 2013
GPA: 2.40/4.0
EMPLOYMENT
Menards, Washington, IL and Marion, IL
Sales Associate, April 2011 – August 2013
 Assisted customers with knowledge and selection of merchandise
 Inspected quality and quantity of merchandise
 Developed communication skills to resolve conflicts
Hoerr Construction, Peoria, IL
Laborer, March 2008 - August 2013
 Operated and maintained heavy equipment
 Proposed ideas to better improve productivity
 Supervised the controls of machinery
Bernardi’s Family Restaurant, Washington, IL
Assistant Kitchen Manager, October 2007 - April 2011
 Maintained the inventory for the kitchen
 Estimated monthly inventory costs
 Supervised several employees at a time
ACTIVITIES
Engineering Student Council, August 2013-Present
 Elected Chair of the Service and Community Outreach Committee
 Coordinated various college wide events
 Appointed students to perform numerous tasks
SAE Saluki Baja Team, August 2012 – Present
 Elected Treasurer for the 2013-2014 year
 Repaired rack and pinion for the front suspension at 2012 Competition
 Assisted in the frame design using SolidWorks modeling
 Designed, fabricated, and tested many structures for a vehicle
31
F13-60-Baja
KEEGAN GEORGE THOMAS LOHMAN
kgtlohman91@siu.edu
PERMANENT ADDRESS:
Hillsboro, IL 62049
(217) 532-3276
COLLEGE ADDRESS:
Carbondale, IL 62901
(217) 556-6180
OBJECTIVE
To obtain a job in Mechanical Engineering beginning in summer 2014.
EDUCATION
SOUTHERN ILLINOIS UNIVERSITY (SIU)
Carbondale, IL
Bachelor of Science Degree in Mechanical Engineering
Class Level: Senior
Graduation Date: May 10, 2014
Dean’s List: Fall 2010, Spring 2011, 2012, 2013
Overall GPA: 3.606/4.000
SKILLS
SolidWorks
Autodesk Inventor
Microsoft Word
Microsoft Excel
RELEVANT COURSEWORK
Statics & Dynamics
Mechanical Analysis & Design
Electrical Circuits
Materials Selection
Heat Transfer
PROFESSIONAL EXPERIENCE
AutoCAD
Microsoft PowerPoint
Mechanics of Materials
Thermodynamics I & II
Internal Combustion Engines
Machine Design
Fundamentals of CAD/CAM
TIG/MIG Welding
Mills and Lathes
Materials Engineering
Fluid Mechanics
Manufacturing Methods
Mechanical Engineering Controls
Mechanical Engineering Design
Mechanical Engineering Technician Intern
Cummins
May 29, 2013 to August 16, 2013
Sub-Contractor
Dowalder Construction
Summers (June 2009 – August 2012)
Sub-Contractor
Holcomb Construction
Summers (June 2009 – August 2010)
Sales Associate and Customer Assistant
Ace Hardware
May to June 2009
February to August 2008
HONORS/AWARDS


Louis & Temple March Scholarship
Selma J. Harke Scholarship


Donnie L. Butron III Memorial Scholarship
Joe Rapp Memorial Scholarship
 ACTIVITIES
 SAE Saluki Baja, SIU, President
 Treasurer
 Member
 American Society of Mechanical Engineering (ASME), SIU, Member
 Hillsboro Volunteer Fire Department, (HVFD), Volunteer Firefighter
 Venture Crew
 SIU Hoverclub, SIU, Vice President
 Boy Scouts of America, (BSA), Life Scout
32
April 2013 to Present
August 2012 to April 2013
August 2010 to Present
August 2010 to Present
February 2013 to Present
Fall 2007 to February 2013
August 2010 to May 2011
Fall 2002 to Fall 2006