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2013 Baja Car Rear Suspension Redesign

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2013 Baja Car Rear Suspension Redesign 2013 Baja Car Rear Suspension Redesign A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by Sahil Patel September 2014 Thesis Advisor: Dean Allen Arthur ACKNOWLEDGMENTS I would like to thank Dean Allen Arthur for his ongoing support, patience, and guidance throughout this project. I would also like to thank Mr. Ronald Hudepohl, Mr. Douglas Rife, Mr. David Conrad, and Mr. Bill Hansel for their assistance with the production and assembly. This project would not be able to have been completed without them. ii TABLE OF CONTENTS ACKNOWLEDGMENTS ........................................................................................................ II TABLE OF CONTENTS ........................................................................................................ III LIST OF FIGURES ............................................................................................................. IVV ABSTRACT ............................................................................................................................. V INTRODUCTION .................................................................................................................... 1 PROBLEM STATEMENT........................................................................................................................................ 1 INTERVIEWS ....................................................................................................................................................... 1 CUSTOMER REQUIREMENTS ............................................................................................. 2 PROOF OF DESIGN ................................................................................................................ 3 PREVIOUS DESIGN ............................................................................................................... 4 RESEARCH .............................................................................................................................. 5 DESIGN PROCESS.................................................................................................................. 8 REFERENCES ....................................................................................................................... 11 APPENDIX A - MANUFACTURING AND ASSEMBLY .................................................. 12 APPENDIX B - BUDGET...................................................................................................... 17 APPENDIX C - QUALITY CONTROL ................................................................................ 18 iii LIST OF FIGURES Figure 1 – List of Customer Requirements……………………………………………………2 Figure 2 – Figure 2 – Proof of Design ….…………………………………………………….3 Figure 3 – Previous Linkage Mounting Points ……………………………………………….4 Figure 4 – Double A-Arm Suspension………………………………………………………...5 Figure 5 – MacPherson Strut Suspension……………………………………………………..6 Figure 6 – Multi-Link Suspension…………………………………………………………….7 Figure 7 – Motion Sketch of Rear Side Wheel ……………………………………………….8 Figure 8 – Motion Sketch of Camber Change…………………………………………….......9 Figure 9 – Table with New Mounting Points………………………………………………….9 Figure 10 – 3D Final Model………………………………………………………………….10 Figure 11 – Dynamic Mass in Rear Axle…………………………………………………….10 Figure 12 – von Mises Stress Analysis………………………………………………………11 Figure 13 – Bottom Mounting Bracket………………………………………………………12 Figure 14 – Top Mounting Bracket………………………………………………………….13 Figure 15 – Bottom Link……………………………………………………………………..14 Figure 16 – Top Link………………………………………………………………………...15 Figure 17 – Bung Fitting……………………………………………………………………..16 Figure 18 – PVC Pipes……………………………………………………………………….18 iv ABSTRACT The Society of Automotive Engineers (SAE) hosts a yearly intercollegiate Baja race at various locations throughout the nation. Every college that chooses to compete in this event assembles a team of undergraduate and / or graduate students to compete. This competition will include competitions such as acceleration, hill climb, land maneuverability, suspension and endurance. I will work on the redesign of the rear suspension that will be safe, reliable, cost effective, and easy to maintain. The suspension redesign will be my senior design project. v 2013 Baja Car Rear Suspension Redesign Sahil Patel INTRODUCTION PROBLEM STATEMENT Design an improved rear suspension in the 2013 UC Baja Car. The previous rear suspension design of the 2013 Baja Car has an understeer causing poor handling. The new design of the rear suspension must have a roll center of the rear suspension that is closer to the current center of gravity which is 24”. The relationship between the roll center and the center of gravity creates a moment on the vehicle in turns. The greater the distance between the roll center and the center of gravity the greater the moment the vehicle must overcome (2). INTERVIEWS Ricardo Hinojosa was a former Bearcats Baja member, class of 2013. He is knowledgeable on the 2013 car due to his experience from building the car. He has expressed his desire to reduce the understeer on the car. According to him, the geometry of the linkages doesn’t match the suspension. This bit of information was important in developing my problem statement revolving around the roll center of the vehicle. Joe Kobs was the former president of the Bearcats Baja team in the year 2014. He helped with the manufacturing of the 2013 as a 4th year Mechanical Engineering Technology student. He stated that the 2013 car also has a problem with understeering. According to him reliability of the suspension is imperative from his previous experience with the team. It was critical to him that I have a design that will be able to withstand the maximum forces during competition. 1 2013 Baja Car Rear Suspension Redesign Sahil Patel CUSTOMER REQUIREMENTS There are two primary customers for this project. The first is the Society of Automotive Engineers (SAE). Every year SAE host an intercollegiate Baja Competition at 3 various locations throughout America. These completions consist of 4 dynamic events; acceleration hill climb, maneuverability, and rock crawl/suspension. On a yearly basis they issue rules and regulations at which a vehicle must adhere to. The second customer will be the University of Cincinnati Bearcats Baja team. They will be using this car for future competitions and also for practice purposes. The following are the requirements that have been determined. 1. Safety The vehicle must be safe to operate. Vehicle must adhere to SAE Baja rules. 2. Reliable Must support person 200 lbs. weight in seat. The design must be able to last in a SAE Baja race. The camber angle must change less than 5° in the travel motion. The travel motion of the rear wheels must at least be within the shock limit of +4.00 inches and -0.50 inches vertically. 3. Easily maintained Quick disconnects for the assembly parts. Must be independent. Can be maintained by using standard tools. Minimal fabrication will done The left and right side must mirror each other 4. Cost Must stay within the allotted budget Figure 1 – List of Customer Requirements 2 2013 Baja Car Rear Suspension Redesign Sahil Patel PROOF OF DESIGN Proof of design will be conducted by performing a test of the travel motion of the newly designed linkages. The travel motion must be willing to travel up from resting position a minimum distance of 4.25 inches. The distance of 4.25 inches is the distance determined by the range of movement in the shock shown in figure 7. Figure 2 – Proof of Design 3 2013 Baja Car Rear Suspension Redesign Sahil Patel PREVIOUS DESIGN The previous design of the rear suspension linkages did not form a roll center. The outer linkage mounting points (side mounted wheel side) were closer in the Y axis than the inner mounting points (side mounted to the chassis), as shown in the figure below. The outer side distance is 5.5 inches and the inner side is 5.75 inches. Figure 3 – Previous Linkage Mounting Points This results in a roll center that does not exist. When this happens the forces in a turn go in two different directions. The forces going in the two different directions assist in the issue of the understeer on the car (4). 4 2013 Baja Car Rear Suspension Redesign Sahil Patel RESEARCH Double A-Arm Suspension This type of suspension is also referred to as the double wishbone. It This system is heavier utilizes a dual “A” shaped arm. The two arms are on the same and takes up more horizontal plane and have a shock absorber running through the space than the arms. The top arm will be shorter than the bottom arm (4). Each arm counterparts. This is has two mounting points connected to the frame and one joint at suspension is the knuckle. This type of system is good for increasing negative complex and has camber angle. In turn there are great traction qualities for turns. The multiple parts camber of the tire is also easily adjustable in this type of suspension. associated with it. The costs associated with this particular suspension are higher than the counterparts. Any maintenance for the double A will be time consuming. (4) Figure 4 – Double A-Arm Suspension 5 2013 Baja Car Rear Suspension Redesign Sahil Patel MacPherson Strut Suspension The MacPherson Strut system is very common for modern day cars. It is difficult
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