IUPUI Moonbuggy Design and Race Project

ME 450 Computer-Aided Engineering Analysis

Instructor: Dr. Nematollahi Spring 2005

Department of Mechanical Engineering, IUPUI Presented by Andrea Geyer

May 2, 2005
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Introduction
Students from the Department of Mechanical Engineering and AIAA IUPUI Moonbuggy Design and Race Team
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Purpose
Design, build and race Lunar Rover inspired vehicle
2 person Human powered Collapsible

Main Targets
Collapsible
Buggy folds in half to create 4 cube

Quick Assembly
1 step folding/unfolding

Lightweight
Weighs 150lbs or less

Multiple Gear Ratios

Internal hub gear gives 7 gear ratios
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Main Targets
Collapsible
Buggy folds in half to create 4 cube

Quick Assembly
1 step folding/unfolding

Lightweight
Weighs 150lbs or less

Multiple Gear Ratios

Internal hub gear gives 7 gear ratios
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Frame Redesign
Used less metal in structure Used hollow beams when possible Selected aluminum as structure material

Frame Redesign
Aluminum comparison
6061: tried, tested & proven 6063: readily available

I-beam analysis
Mounting point for front wheels First point of contact

Hub gear mount analysis

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Aluminum Comparison
Created solid 2x4x5 volume Subtracted 1.75x3.75x5 volume from center Modeled as solid, tet10 6063 Aluminum
E=9.993e6 psi

6061 Aluminum
E = 1.0008e7 psi

Determination of force
Based on Newtons 2nd Law
Principal of Impulse and Momentum
t2

d F = (mv ) dt

Fdt = mv
t1

mv1

F (t 2 t1 ) = m(v 2 v1 )

Assuming v1=10 ft/s, v2=0, t2-t1=0.5sec, and m=600lb (18.63 slugs)

m(v2 v1 ) 18.63slugs( 10 ft / s ) = F= = 372.6lb f t 2 t1 0.5s
(With a factor of safety = 2)
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Aluminum Comparison
Two types
6061: tried, tested and proven 6063: more readily available

6061

400-lb force applied at edge Deformation same

6063
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Aluminum Comparison
Two types
6061: tried, tested and proven 6063: more readily available

6061

400-lb force applied at edge Deformation same VonMises stress basically the same

6063

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I-Beam Analysis
Mounting point for front wheels First point of contact with obstacles IGES

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I-Beam Analysis
400-lb applied at holes
VonMises stress well below yield No deformation

400-lb applied at flanges

VonMises stress just above yield Some deformation
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Hub Gear Mount Analysis

Mounting point hub gear Drivetrain forces all meet at this point

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Hub Gear Mount Analysis

Modeled as solid, tet10 180lb applied at cutout VonMises stress beyond yield

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Hub Gear Mount Analysis

Modeled as solid, tet10 180lb applied at cutout VonMises stress well below yield

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Conclusions
6063 Aluminum approved I-Beam will hold up 2nd Design for Hub Gear Mount viable solution

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Thank You!

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