TEAM F13-60-BAJA
FRAME DESIGN
Design Review
Members: Austin Lewandowski (PM)
Steven Baldwin
Preston Mathis
Keegan Lohman
Thang Tran
Kyle Koester
F13-60-Baja
Design Review Agenda
 Design Presentation
o Customer demands (Explain some of the requirements of
SAE competitions which limit certain aspects of the car’s
design)
 House of Quality
o The design of the frame at this point in time (State of project)
 FEA
 Frame design
 Material selection
 Cost Considerations/Funding
 Anticipated Design completion/Project completion
 Questions for Faculty
 Comments/Suggestions
 Closing Remarks
Project Overview
• Building an off road vehicle to SAE specs, with intent to sell to
general public
• Using last years suspension geometry
• Targeting weight loss for the car
• Accomplishing goals through Finite Element Analysis (FEA),
material selection, and improved frame design
3
9
Marketability
5
Weight
4
Durability
3
1
3
1
Performance
3
3
57
3
1
Tech Importce.
9
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
House of Quality
3
9
3
2
3
9
1
9
9
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
Finite Element Analysis
• Performing static analysis, and dynamic loading of frame during
impact
• In process of learning FEA software (Inventor)
• Several transient models researched that we can modify
• samples from auto industry
• Examples from other SAE Baja teams
Similar Vehicles
• Consistent top 5 finisher in
SAE series (durable and
lightweight)
2010 Polaris RZR trailing arm
rear end
Frame Design
• Reproduced front end:
Re-designed rear roll hoop and base frame
4130 Chromoly
[1] 4130 (Chromoly) Normalized Alloy Steel
• 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.
Chromoly is an abbreviation for
chromium, molybdenum steel. It is not as
lightweight as aluminum alloys, but has the
advantages of high tensile strength and
malleability. It is also easily welded and is
considerably stronger and more durable than
standard 1020 steel tubing.
[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
Chemistry
Iron (Fe)
97.3 - 98.22%
Carbon (C)
0.28 - 0.33%
Chromium (Cr)
0.8 - 1.1%
Manganese (Mn)
0.4 - 0.6%
Molybdenum (Mo)
0.15 - 0.25%
Phosphorus (P)
0.035% max
Sulphur (S)
0.04% max
Silicon (Si)
0.15 - 0.35%
Questions
• Do the dynamics of the car still need to be analyzed when the
•
•
•
•
goal of our design is to simply reduce the overall car weight?
What are specific considerations when analyzing the dynamics
of the frame (FEA)?
Are there any more efficient methods to reduce weight?
What gaps do you see in our FEA/design model that could make
a difference?
What are the keys to writing an outstanding final proposal?