AME 4163

Dr. Farrokh Mistree

Assignment A10
Zebu BAJA UFTM

I affirm that I have completed this assignment with integrity.

December 9, 2014

1. Introduction
Baja SAE is an intercollegiate design competition run by the Society of Automotive
Engineers (SAE). Teams of students from universities all over the world design and build
small off-road cars. The cars all have engines of the same specifications. As of 2009 the engine
has been an unmodified Briggs & Stratton Intek 20 single-cylinder with a displacement of 305cc
and power output of approximately 10 bhp (7.5 kW).
The goal in Baja SAE racing is to design, build and race off-road vehicles that can
withstand the harshest elements of rough terrain. The vehicles used in Baja SAE racing are often
similar in appearance to dune buggies. Before 2007, the events were called "Mini Baja."
Zebu BAJA is the name of the team where I had worked for approximately two and a half
years. This team is part of the University of Triangulo Mineiro (UFTM) where I used to study
before coming to United States of America.
This assignment has the overall goal to show the improvement in two subsystems of a
BAJA car, which are Brake System (2012-2013/1) and Front Suspension System (2013/2
2014/1).

2. Team Contract and Project Organization

2.1. Team member qualifications
The brake system was responsibility of two people when I joined the team. The director
Rafael Waechter and me, Joao Vitor Ricciardi. Rafael Waechter was a junior mechanical
engineering student while I was a sophomore mechanical engineering student. None of us had
any vehicle dynamics experience and were just learning about the system.
The front suspension system was responsibility of four people when I joined this
subsystem. I was the director, Fernando Lima, Fabio Carvalho and Felipe Sousa. That time I and
Fabio were junior level, Fernando Lima was senior level and Felipe Sousa was sophomore level.
The basic knowledge of vehicular dynamics was obtained through the book GILLESPIE,
Fundamentals of Vehicle Dynamics.
2.2. Team Structure
a)

Main director
The Main Director was responsible for organizing the team, manage tasks and important

documents.
b)

Manufacturing
The members of Manufacturing subsystem were responsible for create the documents,

manage time, obtain resources and manage them.

c)

Chassis
The members of Chassis subsystem were responsible for calculations on the tubular

structure and follow all the SAE rules for the Chassis geometry.
d)

Powertrain
The members of Powertrain subsystem were responsible for motion the car, designing a

transmission system to transfer the power motion to the wheels.

e)

Front suspension

The members of Front Suspension subsystem were responsible for the possible primary
impacts, developing a suspension geometry which function was pilots comfort and impact
absorption.
f)

Rear suspension
The members of Rear Suspension subsystem were responsible for the possible secondary

impacts, developing a suspension geometry which function was pilots comfort and impact
absorption.
g)

Steering wheel
The members of Steering Wheel subsystem were responsible for the maneuverability of

the BAJA, applying calculations of efforts and geometry to obtain an optimal relation steer angle
by turning radius.
h)

Electronic and workmanship

The members of Electronic and Workmanship were responsible for all kind of electronic

devices and to make our BAJA good looking.

j)

Brake
The members of Brake subsystem were responsible to calculations of a safe brake system

following the SAE rules about braking all four wheels at the same time.
2.3. Teams Rules
Each subsystem had a director responsible for teaching the other members in the same
subsystem. Every month each director and members were required to send a worksheet about
everything that was done and what will be done in the next month to the responsible in the
Manufacturing subsystem. Doing this the plan of action of the team was created and the Gantt
chart generated. Each member of the team must spend at least five hours per week working or
studying about improvements in a BAJA car.

Figure 1 Schedule and Gantt chart of ZEBU BAJA in Portuguese

2.4. Team Communication

All students involved in this project were studying in the same university and it was easy
to meet with them at any time. Scheduled meetings were done twice per month to discuss critical
points. A Facebook group was used to share documents and for quick communication.

3. Development of Project Requirements

All members had some days to study improvements in their subsystem. Especially in the
subsystems where I worked the main improvements were focused in better materials. The
financial resources were limited for each group based in the importance of each subsystem. The
financial resource to build the entire car is shown in the figure below. The numbers below the
name of the source are the value received in Reais (Brazilian currency).

*Patrocnio = Sponsorship
* 1 dollar = 2.70 reais

Patrocnio
6200
17%

UFTM
16000
43%

UFTM
FAPEMIG
Patrocnio

FAPEMIG
15000
40%

Figure 2 Resource distribution

Figure 3 Costs divided in subsystems

*Freio = brake, Direo = steering wheel, Chassi = chassis, Suspenso = suspension, Eletrnica & Acabamento =
electronics and workmanship, Custo Total = entire cost, Peas Comerciais = commercial parts, Matria Prima = raw
material, Porcas & Parafusos = nuts and bolts.

How the suspension system is divided by front and rear suspension subsystem, the
available amount of money for the front suspension was not a lot, on the other hand, the brake
system had the necessary amount to change some parts.
Based in the financial resource for each subsystem and competitions rules the
requirement list for brake and front suspension system were created.
Table 1 Front suspension and brake subsystems requirements list
Zebu Baja UFTM

Requirements List

2012-2014

Front Suspension and Brake subsystems

Changes

D/W
D
W
D
D
W
D
W
D

Requirements
Safety
Comfort
Absorb impacts:
Frontal Impact
Vertical Impact
Lateral Impact
Longevity:
Operable for at least 3 days of competition
Life time greater than 2 competitions
Brake the four wheels at the same time

x. References
http://en.wikipedia.org/wiki/Baja_SAE

Responsible
Suspension and Brake members
Suspension and Brake members
Suspension members

Suspension and Brake members

Brake members