Finite Element Analysis of Mini Baja Frame

Ariana L. Gonzalez April 29, 2003 MECE

Problem Statement

The Mini Baja Frame needs to withstand any collision that it might be subjected to as part of the testing process or competition. Four impact scenarios were analyzed to ensure the frame design will not fail.

Front Impact Rear Impact Side Impact Roll Over

Material Properties

The frame material is 4130 N Chromoly Steel with an outer diameter of 1.125 and wall thickness of 0.058 but was modeled as solid rods with1.125 diameter. Elastic Modulus 29 * 10^6 psi Poissons Ratio .25 Yield Stress 1.16 * 10^5 psi

Pro/Engineer Model

Actual Frame Design

Calculation of Front Impact Force

Front Im pact Analysis As sumptions : 1. Vmax = 26 mph (maximum car speed) 2. Mtotal = 600 lbs (total car mas s including driver) 3. t = 0.1 s (total time f rom top speed to f ull stop)
vi 26mph v 0mph Mt otal 600 lb t 0.1sec a v vi t

v = vi + at v = f inal v elocity vi = initial v elocity t = total time a = car decceleration

ft a 381.333 2 s F Mt otal a F 7.111 10 lbf In this case, F is the total f orce of impact for a f ront collision.
3

Forces and Constraints

The force of 7111 lbf was divided by four and applied to the four front most points of the car (1777.75 lbf). The rear most points of the car was constrained to prevent movement.

Finite Element Analysis of Front Impact

Close Up

Calculation of Rear Impact Force

Re ar Im pact Analysis As sumptions: 1. Vmax = 33 mph (average max imum s peed of other cars) 2. Mtotal = 600 lbs (total car mass inc luding driver) 3. t = 0.1 s (total time from top speed to full braking)
vi 33 m ph v 0m ph Mt otal 600 lb t 0. 1 sec a v vi t ft s
2

v = vi + at v = f inal v elocity vi = initial velocity t = total time a = car decceleration

a 484

F Mt otal a F 9. 026 10
3

lb f

Forces and Constraints

The force of 9026 lbf was divided by four and applied to the four rear most points of the car (2256.5 lbf). The front most points of the car was constrained to prevent movement.

Finite Element Analysis of Rear Impact

Close Up

Finite Element Analysis of Rear Impact

Calculation of Side Impact Force

vi 33mph
Side Im pact Analysis As sumptions: 1. Vmax = 33 mph (average max imum s peed of other cars) 2. Mtotal = 600 lbs (total car mass inc luding driver) 3. t = 0.1 s (total time from top speed to full braking)

v 0mph Mt otal 600 lb t 0.1 sec a v vi t ft s

2

v = vi + at v = f inal v elocity vi = initial velocity t = total time a = car decceleration

a 484

F Mt otal a F 9.026 10 lbf

3

Forces and Constraints

The force of 9026 lbf was divided by four and applied to the right most points of the car (2256.5 lbf). The left most points of the car was constrained to prevent movement.

Finite Element Analysis of Side Impact

Close Up

Calculation of Roll Over Force

Roll Over Analysis
vi 26 m ph

As sumptions: 1. Vmax = 26 mph (maximum speed of car) 2. Mtotal = 600 lbs (total car mass inc luding driver) 3. t = 0.1 s (total time from top speed to full braking)

v 0m ph Mt otal 600 lb t 0. 1 sec a v vi t

v = vi + at v = f inal v elocity vi = initial velocity t = total time a = car decceleration

ft a 381. 333 2 s F Mt otal a F 7. 111 10 lb f

3

Forces and Constraints

The force of 7111 lbf was divided by two and applied to the top most points of the car (3555.50 lbf). The bottom of the car was constrained to prevent movement.

Finite Element Analysis of Roll Over

Close Up

Alternative Design

FEA of Alternative

Close Up

Conclusions

The solid model can only be used to determine places where there is a stress concentration. The proposed alternative reduces the stress concentration at desired location.