SAE Mini-Baja

Purdue University
Society of Automotive Engineers
Fall 2005 Newsletter

585 Purdue Mall, Room 46

West Lafayette, Indiana 47906
Phone: (765) 494-2444
Website: http://widget.ecn.purdue.edu/~sae
President: Dave Austin E-Mail: daustin@purdue.edu
Faculty Advisor: John Nolfi E-Mail: nolfijg@purdue.edu

Objective
The purpose of the SAE Mini-Baja competition is to simulate real-world
engineering design projects and the challenges associated with them. Each
team is competing to have its design accepted for manufacture by a fictitious
firm. A student team must design, build, test, promote and compete with a
vehicle that meets the rules specified by SAE. The team must also generate
its own financial support, as well as manage their educational priorities.
The vehicle itself must meet certain criteria. Each team’s goal is to
design and build a prototype of a rugged, single seat, off-road recreational
vehicle intended for sale to the non-professional weekend off-road
enthusiast. The vehicle is restricted to a ten horsepower Briggs & Stratton
engine, which cannot be modified or optimized in any way. For safety,
guidelines for various parts of the design are outlined; however the majority
of the design is open to any ideas the team can come up with.
Historically, Purdue Mini-Baja has brought two cars to each
competition. One being a new design, built from the ground up and the other
being a redesign from the prior year. However, due to extensive rule
changes regarding the chassis rules, we are unable to reuse the chassis from
last year. This means that we will be designing and building two brand new
cars this year, the Barracuda and the Squirrel.

Drive Train
The main goal of the 2005-2006 drive train teams is to design an
efficient, lightweight, and durable drive train package. The Barracuda team
will be utilizing a Polaris belt driven, continuously varying transmission (CVT)
and a high-low speed transfer case. The Squirrel team will be using a five-
speed manual transmission from a Honda dirt bike. Both cars will be rear
wheel drive. All the drive train components will be modeled using
ProEngineer and analyzed using ProMechanica. The teams are also
researching various types of constant velocity and universal joints to
complete the drive train package. Research is also underway to design a
more reliable and effective braking system.

Engine & Transmission Design ADAMS Model of Front

Suspension w/ front drive
Suspension
The suspension geometry design for both vehicles is currently
underway. The suspension geometry is being optimized in ADAMS Car
software and will be modeled in ProEngineer before the prototype is built.
The vehicles will have around 12” of suspension travel with a minimal
amount of bumpsteer. The suspension teams are researching different
shocks, springs and materials in efforts to shave weight while maintaining
the dynamic performance of the vehicles.

Chassis before assembly Front upright being CNC

machined
Frame
The chassis teams are working hard to insure the safety of the driver,
while maximizing comfort; to do this the teams are improving the legroom
and the overall ergonomics of the cockpit area. The teams must improve
the comfort level and still maintain an aesthetically pleasing and rugged
design. The chassis will be constructed of chromoly tubing and TIG welded
together. The chassis will be analyzed using ProMechanica for various
impacts and loading scenarios to insure the structural integrity. The chassis
design of the Purdue Mini-Baja vehicles also includes front, rear, and side
protection to protect the driver and vehicle from collisions during the
endurance race, in the form of a front bumper, rear bumper, and nerf bars
integrated into the design of the frame.

Competition
There are three annual Mini-Baja competitions in North America of
which Purdue University attends two every year. Last year, Purdue brought
two vehicles, the Bandit and the Scorpion, to compete in the West and
Midwest competitions. Competition is grueling with over 140 universities
from all over the world competing in the main Mini-Baja competition at
Midwest. Similarly in the West competition, nearly 140 universities
competed with the Bandit placing 7th overall and the Scorpion placing 32nd
overall. The Bandit previously won the TARDEC award presented by the US
Army TACOM for outstanding display of off-road mobility for small vehicle
platforms. The Bandit also won the Polaris innovative suspension award
given to the team with the most innovative and unconventional suspension
design. In the Midwest competition, Bandit placed 35th overall and the
Scorpion placed 65th.
At each of these competitions, the teams are tested in various areas
that include: static, dynamic, and endurance events. The static evaluation is
composed of three major parts, two of which are written. A design report is
submitted for the vehicle that describes the design intent of the vehicle and
the engineering that went into the design. A cost report is submitted for the
vehicle that documents the production cost of the vehicle and prototype
cost. During static judging the vehicle is evaluated by several judges on
aspects such as the vehicle’s originality, feasibility of mass production, driver
comfort, structure, and serviceability. The dynamic events test the vehicles
on a wide range of terrains that may be encountered in an off road
environment, each testing a specific performance metric for the vehicle. The
dynamic events include maneuverability, acceleration, braking, top speed,
hill climb, sled pull, rock crawling, and a grueling four-hour endurance race.
 Scorpion vehicle during Bandit vehicle during Hill Climb
Acceleration test at Midwest 2005 event at West 2005

Why Support Purdue SAE Mini-Baja?

Purdue SAE Mini-Baja students experience a multitude of real-world
situations throughout the vehicle design and competition process. Purdue
SAE Mini-Baja teaches its members how to apply their classroom
engineering skills to a real-world situation. The members also gain
experience in resource and project management. As a result of the changes
ahead for the up coming academic year, Purdue SAE Mini-Baja has set a goal
of sending multiple cars to both the West competition in Portland, Oregon
and the Midwest competition in Milwaukee, Wisconsin during May of 2006.
In order to achieve this ambitious goal, ongoing support from sponsors in
the form of supplies and monetary donations are necessary. If you would
like to contribute, please contact Dave Austin, listed on the cover of the
newsletter. With your help we will achieve our goals of competing and
gaining beneficial experience.

For updates throughout the year, visit our web page-

http://widget.ecn.purdue.edu/~sae
 Sponsors and Contributors
• Purdue University School of • Lincoln Electric
Mechanical Engineering • Timken
• Purdue Grounds Department • Hoffco/Comet
• ABBCO • Martin Custom Products
• DaimlerChrysler • Motion Industries
• Toyota • B & R Gear
• Purdue Engineering Student • Lane Automotive
Council • McCord Tire
• ArvinMeritor • Aurora
• Cummins • Earl’s
• Bosch Braking Systems • Visteon
• Fairfield Manufacturing • MAC Construction
• Carpenter Technology Corp. • Cintas Corp.
• RC Laser • Von Duprin
• Detroit Diesel • PTC
• NTN • Dayco Belts
• AED • Digatron
• Top Notch Tool • American Technology
• Express Signs • Van Sandt
• Briggs and Stratton • International
• Douglas Wheel • John Deere
• AFCO Racing • Emerson Electric Co.
• Suspension Spring Co.