Chassis

Front Suspension

Transmission

• Thinner walled tubes to facilitate weight reduction without compromising durability • Full AISI 4130 normalized steel • Increased space for easier access to the fuel tank • Maintain structural stiffness of the rear to support the roll cage (FAB bracing) • Torsional rigidity of 883 lb*ft/deg

• Independent double wishbone suspension • Adjustable static caster, camber, and toe angles • Compression, rebound, and preload adjustability, and interchangeable springs • Optimized control arm design for functionality and cost reduction Control Arm Analysis • Shock placement close to ball joint housing for reduced bending load • 12o pro-dive improves jump survivability • Geometry designed for minimal bump steer and lateral scrub

Steering • Fast ratio rack and pinion: 180 degrees lock-to-lock • Ackerman deviation of approximately 2.5 degrees • Steering column mounted at 25 degrees

Brakes

• Accessible engine mount and chain • Adjustable shifter design • 6-speed manual transmission

•Lightweight, durable, and recyclable Thermoplastic Polyolefin (TPO) body panels, aluminum belly pan and firewall

•CNC machined molds made from medium density fiberboard (MDF) to save fabrication time, while facilitating inclusion of complex surface design

•Inexpensive vacuum forming process was employed to fabricate the body panels

•Water based paints to ensure environmental sustainability

• Easily accessible pedals, light weight pedals • Dead pedal for driver comfort • Improve serviceability and manufacturability • 3:0:1 for better ergonomics

Seat Design • Hammock style seat design • Integrated head rest • Obus Forme for driver comfort • Multi-hole tabs for adjustable height and position • Load-rated locking carabineers

Unique Rear Suspension & Drive Train

• Highly progressive shock angle • Fully adjustable rebound and compression damping • Fully independent suspension without compromising efficiency • Eccentric cam on one side only to adjust chain tension • Use of constant velocity joints • Hollow mid-axle for weight saving • Designed to eliminate bending loads in the axle • Sprocket driven • Gun-drilled and heat treated AISI 4340 steel stub axles • Constant velocity joints allow efficient power transfer and enable independent suspension travel • Tubular light weight mid-axle

Body

• Lightweight, durable, and recyclable Thermoplastic Polyolefin (TPO) body panels, aluminum belly pan and firewall • CNC machined molds made from medium density fiberboard (MDF) to save fabrication time, while facilitating inclusion of complex surface design • Inexpensive vacuum forming process was employed to fabricate the body panels

Team Members

Al Makke JuanPalacio Mike Doody

Guo Yu Lane Landry

Maoxin Gong

Dr. Bruce Minaker Mr. Bruce Durfy

Advisors

Comparison Between Empirical Data and Simulation

Rear Suspension – Crash Analysis

Applied Load

Acceleration: Rear Impact

Acceleration: Side Impact

Fully Independent Suspension Configuration

Deformation - Rear Impact Loading – 30kN

Deformation - Side Impact Loading – 30kN

Fully Independent Rear Suspension

Von Mises Stress due to Rear Suspension Loading (Torsion)

• 2250 lbs applied oppositely in the z direction at the rear suspension mounts • Torsional rigidity of 883 lbs*ft/deg

Rollover Effect on RHO Members

• 2 forces applied perpendicularly to the high bends of the RHO members of a value of 2 g’s • Maximum Von-Mises stress: 100 Mpa (Safety factor of 4.3

Modal Analysis: Natural Frequency

• Von-Mises stresses at natural frequency of 55 Hz

Chassis

Front Suspension & Steering

Toe angle change vs. wheel travel

•Bump steer minimized for improved handing in rough terrain

Vertical roll center location with respect to roll angle

Ackerman deviation of approximately 2.5º

•Low Ackerman deviation for improved handling in low speed conditions Suspension & Steering Assembly

Stress Analysis on Brake pedal

Transmission

Brake Pedal Design

Traction, Resistance, Tire limit, and Available Force as a Function of Longitudinal Vehicle Speed

Powertrain Seat

Brakes

Brake Pedal Assembly

Vehicle Shifting Sequence Time History of Vehicle Acceleration

Time History of Vehicle Speed

“Hammock” Style Seat Design

Light weight Coupler shaft 6 Speed Manual Transmission with Coupler Shaft