UNIVERSITY OF SOUTH AFRICA

COLLEGE OF SCIENCE ENGINEERING AND TECHNOLOGY

SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

MINI – BAJA 2018

UNISA TEAM 3
DESIGN REPORT

Team Members:
- Jarryd Brown (42013011)
- Happison Tasara (58157514)
- Thoriso Boshielo (50349589)
- Mpho Molokomme (46551425)
- Daniel Mabengo (48591238)
- Christelle Lusamba (48554006)
- Thabo Mokoena (50943855)
- Jabulani Mahlangu (50245910)
- Shosha Mzuyanda Louis (44576803)

Lecturer: Dr. Sithebe

October 2018
Mini-Baja 2018 – Design Report

INDEX

1. INTRODUCTION ...................................................................................... 1

2. OBJECTIVES OF THE DESIGN ............................................................ 1

3. VEHICLE DESIGN ................................................................................. 1

3.1 MAIN DESIGN ADJUSTMENTS ........................................................ 1

3.2 FRAME DESIGN ................................................................................ 2
3.2.1 Material selection .................................................................... 2
3.2.2 Welding ................................................................................... 2
3.2.3 Tests performed on the frame ................................................. 3

3.3 SUSPENSION .................................................................................... 3

3.3.1 Front suspension ..................................................................... 3
3.3.2 Rear suspension ..................................................................... 5
3.3.3 Shock absorbers ..................................................................... 5

3.4 STEERING SYSTEM .............................................................................. 6

3.4.1 Steering column ...................................................................... 6
3.4.2 Tie rods ................................................................................... 6
3.4.3 Correct steering angle .............................................................. 7

3.5 DRIVE TRAIN ........................................................................................ 8

3.5.1 Engine ..................................................................................... 8
3.5.1.1 Gear box design .................................................................... 9
3.5.1.2 Speed and Acceleration calculations ..................................... 11
3.5.2 Brakes ...................................................................................... 11
3.5.3 Brake configuration ................................................................. 12

3.6 ELECTRICAL SYSTEM ......................................................................... 13

4. CONCLUSION ........................................................................................ 14

5. REFERENCES ....................................................................................... 15

6. LIST OF TABLES.................................................................................... 15

7. LIST OF PICTURES ............................................................................... 15

APPENDIX ............................................................................................... 16

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Mini-Baja 2018 – Design Report

1. INTRODUCTION

The National Diploma in Mechanical Engineering curriculum covers a theoretical part

and a practical facet whereby students have a hands-on experience on the kind of
challenges they may face in their field of study. The inception of SAE BAJA
competition in South Africa and its adoption by UNISA has brought a paradigm shift
in the participating engineering students’ approach to design projects thus enabling
them to strengthen their technical as well as soft skills like team work and
presentation skills amongst others.

This report is a summary of steps taken in the design of a Mini-Baja Vehicle. The
purpose of the competition is to simulate a real-world engineering design project in
which university teams design and manufacture a prototype of a rugged, single-seat,
off-road recreational vehicle intended for the non-professional weekend off-road
enthusiasts.

2. OBJECTIVES OF THE DESIGN

The design should be durable, safe and easy to maintain and must be able to
negotiate rough terrains in any weather condition by taking into consideration the
requirements of the roll cage, front and rear suspension systems, steering and drive
train. Satisfying these conditions will ensure that we meet SAE’s rules and
regulations in terms of safety of occupant, ease of manufacturing, cost, weight
(dynamic behaviour) and overall aesthetics and performance.

3. VEHICLE DESIGN

3.1 MAIN DESIGN ADJUSTMENTS

The main design puts an emphasis on a completely new 2018 vehicle which has
lighter and more rigid and aesthetic-orientated frame, a more robust suspension
design, and a more versatile drive train. With easy access to a tube bender, our
team was able to increase the number of bends (85o and 44,73o respectively) in the
vehicle and in turn use more continuous members. The weight of the car was also
drastically reduced. In addition to these design adjustments, the team also aimed at
correcting the failure that occurred during last year’s competition.

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Mini-Baja 2018 – Design Report

3.2 FRAME DESIGN

3.2.1 Material selection

Material selection is a key factor in the designing of the frame as it plays a role in the
safety, reliability, performance and strength of the roll cage. The following table
illustrates common tube materials under different categories.

Material AISI 1018 AISI 4130 Duplex 2205 Steel Duplex 2205 Steel

Outside diameter 2.540 cm 2.540 cm 2.540 cm 2.540 cm

Wall thickness 0.2 cm 0.2 cm 0.2 cm 0.1 cm

Bending stiffness 2791 Nm2 2791 Nm2 2171 Nm2

Bending strength 390 Nm 382 Nm 454 Nm 260.4 Nm

Weight / meter 1.6615 kg/m 1.2444 kg/m 1.1475 kg/m 0.8790 kg/m

Table 1: Categories of Common Tube Materials

In our case, we recycled half of the material used in the previous Baja and used the
AISI 4130 steel (2mm) to manufacture the back part of the frame.

3.2.2 Welding

The final roll cage was fabricated by modifying the back part of last year’s design.
Considering the compatibility along with cost and availability, the AISI4130 could be
welded by all commercial methods. The Lincoln Electric 200c® T02 TIG welding
machine was used to assemble the frame.

Picture 1: Lincoln Electric 200c Welding Machine

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Mini-Baja 2018 – Design Report

3.2.3 Tests performed on the frame

Finite Elements Analysis was performed on the vehicle using Autocad Inventor, the
rendering of which, together with the views of the frame, are attached in the
appendix part of this report. Nevertheless physical properties analysis of the frame
gave the following results:

3.3 SUSPENSION

A Baja suspension must be able to provide the ability to compete in every event with
practical functionalities such as ground clearance and suspension travel which
results in good comfort and control to the driver allowing proper navigation in rough
terrain.

3.3.1 Front suspension

The front suspension is a short & long A-arm wishbone arrangement. In order to
compensate for dive-effects during aggressive cornering, the camber angle for the
front suspension has been set to 0o at ride height. In addition to that, the camber
angle has been set to decrease when the shock absorber compresses during turns.

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Mini-Baja 2018 – Design Report

Our team opted for a double-wishbone because it provides more design choices
than some other types do. It is fairly easy to work out the effect of moving each joint,
so the kinematics of the suspension can be tuned easily and wheel motion can be
optimized. It is also easy to work out the loads that different parts will be subjected to
which allows more optimised lightweight parts to be designed. They also provide
increasing negative camber gain all the way to full jounce travel, unlike
the MacPherson strut, which provides negative camber gain only at the beginning of
jounce travel and then reverses into positive camber gain at high jounce amounts.

Picture 2: Double-A-arms (Wishbone) suspension used in our baja

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Mini-Baja 2018 – Design Report

3.3.2 Rear suspension

Rear suspension type all depends on what your

design intention is. If your intention is cornering
ability, than a double wishbone or 5-link is
probably your best option. Many teams however
consider bump taking a major goal, seeing as
we race off-road. In that case, a double
wishbone is not as ideal, seeing as its front to
rear motion is linear, and normally more or less
vertical. For tackling obstacles, many people feel
that the wheel should travel in an arc. This is
where a 3-link, independent trailing, or trailing Picture 3: Rear suspension in our Baja

swing arm (non-independent) excels. The majority of teams choose a three link since
it offers a compromise between the 2.

3.3.3 Shock absorbers

There is nothing like the best shocks. We had to choose according to our
requirements, depending upon the factors of preload and maximum load the shock
can withstand and its rate of compression.

Fox float 3, fox float evol are widely used in

Baja ATVs. But the fox float 3 shocks do not
rebound properly after compression. We have
chosen the Endurance© shock absorbers for Picture 4: Endurance© Shock absorber

durability and stiffness reasons. This freed up an extra spare so we had

appropriately valved shocks for front and back.

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Mini-Baja 2018 – Design Report

3.4 STEERING SYSTEM

The steering system’s objective is to provide directional control of the vehicle while
withstanding high stress in off-terrain condition in order to reduce steering effort and
providing good response from the road to the driver.

We elected for the fast ratio rack-and-pinion which travels from one end to the other
in 2.5 turns of the pinion with a resultant rack linear motion of 8cm. Steering ratio of
4:1 is achieved, which means for every 180 degree of rotation of steering wheel tires
will be turned by 45 degrees.

3.4.1 Steering column

We have opted for a fixed steering rod since our Baja is spacious enough to
compensate steering adjustment by means of seat adjustment.

3.4.2 Tie rods

Tie rods connect either end of the steering rack to the steering knuckles on which the
front wheels pivot when the steering wheel is turned. The tie rod has two sections
threaded together, so their length can be adjusted and the front wheels aligned. The
outer section, typically called the tie rod end, is most susceptible to wear and failure.

Though tie rod ends historically required regular lubrication, they are among many
aspects of a modern vehicle’s chassis that are now maintenance-free. When they
fail, however, they can throw off the car’s alignment, cause premature tire wear or, in
the worst cases, separate and cause a loss of control.

In our case, we made sure that our tie rods don’t cause loss of control of the vehicle
by selecting the best ones possible.

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Mini-Baja 2018 – Design Report

Picture 5: Tie Rods used in our vehicle

3.4.3 Correct steering angle

The conditions of perfect rolling are achieved if the axes of the front wheels meet the
rear axis at one point. This is the instantaneous centre of the vehicle. The inner
wheel deflects by a greater angle than the outer wheel. The larger the steering
angle, the smaller is the turning circle. The steering angle of the inner wheel can
have a maximum value of 44 degrees.

Steering specifications are as follows:

Steering ratio 4:1

Rack travel 8cm per 180 degree pinion rotation

Front track width 150cm

Wheel base 177cm

Castor 5o
Steering Axis Inclination 6o

Camber 0 degree in front and 10 degrees in rear

Scrub radius 35 mm

Toe 0 mm

Rack Length 105 cm

Turning radius 3m

Table 2: Steering Specifications

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3.5 DRIVE TRAIN

The main objective of the drive train is to vary the torque in the most effective way
possible. This is being done through proper gear reduction for the needs of the
vehicle in the competition. The adoption of a CVT transmission allowed us to
increase performance and engine life expectancy.

3.5.1 Engine

The engine used is a 10hp Briggs and Stratton Model 19L100 VANGUARD make
with an output of 19Nm torque with the following specifications:

MODEL TYPE DISPLACEMENT BORE/STROKE

19L3-0054GI 305 3.12”/2.4”

COMPRESSION RATIO FACTORY TIMING HP (Gross)

8.1 to 1 23 degree BTDC 10.0HP

OIL CAPACITY FACTORY SET RPM FUEL TYPE

24 Ounces (0.7 litres) 3,800 RPM 87 Octane

Table 3: Briggs & Stratton Engine Specifications

Picture 6: Side Views of the Stratton & Briggs Model 19L engine selected.

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Mini-Baja 2018 – Design Report

The engine was placed over the transaxle. A chain-and-sprocket system is used to
couple the engine with the transaxle and guard was manufactured to enclose the
chain drive as shown below.

Picture 7: Engine mounted on top of the chain-and-sprocket system

3.5.1.1 Gear box design and calculations

Road Coefficient of Friction (fr) = 0.16

Mass of the vehicle (M) = 230kg
Fr = fr x M x g x cos where cos = 30o
Therefore, Fr = 0.16 x 230 x 9.81 x cos30o = 312.6N

Total load: 230kg (Vehicle) + 80kg (Driver) = 310 kg

Weight (R): 310 x 9.81 = 3041N
Static Resistance = R = 0.65 x 3041 = 1976.65N

Vmax of Vehicle = 60km/h

Wheel Radius = 0.3075m
Engine Torque = 19N.m (provided by the manufacturer)

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Mini-Baja 2018 – Design Report

Gradient Resistance = M x g x sin

= 230 x 9.81 x sin30o
= 1128.15 N

Acceleration Resistance =Mxa

= 230 x 4.9
= 1127 N

Ftotal = 1128.15 + 1127 = 2255.15 N

𝐹𝑡𝑜𝑡𝑎𝑙 ×𝑣 2255.15×60
Output Power Required = = = 38.2𝐾𝑤
𝑁×𝑛 3800×0.93

𝑚×𝑔×𝑟(𝑓𝑟𝑐𝑜𝑠𝛼+𝑠𝑖𝑛𝛼)
Maximum Gear Ratio = 𝑇𝑚𝑎𝑥×𝑛

Radius of tyre, r = 0.3075

Mass of vehicle (including the driver), m = 310kg
fr = rolling resistance coefficient = 0.035
 = Maximum Angle of inclination = 30o
 = Efficiency of Manual Gear Box = 0.93

Hence, Maximum Gear Ratio will be:

310 × 9.81 × 0.3075 × (0.035 × 𝑐𝑜𝑠30 + 𝑠𝑖𝑛30)

= 25
19 × 0.93

The smallest gear ratio of the gearbox is given by the equation:

𝜋
30 × 𝑛 × 𝑟
𝑣

n = Speed of the engine (rpm) = 3800

v = Speed of vehicle (kmph) = 60

Therefore the smallest Gear Ratio will be:

𝜋
30 × 3800 × 0.3075 = 2.033
60
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25
Overall Gear ratio = 2.033 = 12.3

Torque for low-end gear (output torque) = T = 12.3 x 0.85 x 19 = 198 Nm

3.5.1.2 Speed and Acceleration calculations

- Max Speed of engine: 3600RPM

- Max Torque of Engine: 19Nm
- Diameter of Wheel: 61.5 cm
- Mass of Vehicle: 230 kg

Considering first gear, the speed of the vehicle will be:

3800
= 152𝑅𝑃𝑀 = 17.4𝐾𝑚/ℎ
25

For acceleration, we will have:

Torque = 19 x 25=475Nm

𝐹 𝑇 475
𝑎= = = = 4.9𝑚. 𝑠 −2
𝑀 𝑀𝑟 310 × 0.3075

3.5.2 Brakes

A brake inhibits motion by absorbing energy from a moving system. It is used for
slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion, most
often accomplished by means of friction.

The chosen hydraulic brake system is controlled by a pedal in conjunction with two
separate master cylinders. The use of two separate master cylinders is a safety
interlink. In case one fails, the other will still be operational. Another advantage of
using dual master cylinders is the ability to adjust brake bias. The brake circuit used
here is of the horizontal split type. This was used due to the fact that the tires have
positive scrub radius. Hence, one cylinder will control the front braking system and
the other the rear system.

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Picture 8: Top Left: Master Cylinders; Top Right: Custom-made brake pedal and its design rendering (above)

3.5.2.1 Brake configuration

- Our pedal is our own customised design

- Master cylinders are of the same dimensions
- An armoured steel braided brake line runs through the length of the vehicle
- The reliability of the breaking system is improved by having separate discs and
callipers on each wheel.

Picture 9: Discs and Callipers on each wheel of the Baja

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Mini-Baja 2018 – Design Report

3.6 ELECTRICAL SYSTEM

Electrical components have been installed in the vehicle for safety reasons. Two kill
switches are mounted with easy accessibility to instantly turn-off the engine in case
of emergency. All electrical components are powered from safely secured 9V
batteries.

The following diagram depicts the electrical circuit of the kill switches:

Picture 10: Electrical Diagram of killer switches

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Mini-Baja 2018 – Design Report

4. CONCLUSION

The All-Terrain Vehicle built by Unisa-Team3 is a result of a collaborative

multidisciplinary team design. Careful consideration was given to the selection of
each material taking into account an optimum strength to weight ratio, durability, cost
effectiveness and feasibility. Before immersing into the actual building of the vehicle,
real-time conditions were simulated using various FEA packages like Solidworks and
AutoCad and critical parts of the vehicle were analysed for safety and optimization
issues. A big number of parts, apart from those bought from trustworthy suppliers,
were manufactured in techniques which can be considered suitable for mass
production of this model, if introduced into the market.

Besides technical issues, the team has also to have skills on others aspects like
managing funds and working with a budget plan, achieving targets within deadlines,
project management, sales and marketing thus making its members competent
system engineers and tech savyy. In other words, this experience made team
members ready for real-time industry challenges.

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Mini-Baja 2018 – Design Report

5. REFERENCES

In no order of importance the following were the material we consulted to compile

this report:

1. Douglas L. Milliken, William F. Milliken: Race car vehicle dynamics. SAE

International Publishers (1995)

2. D. Bastow, G. Howard & J.P. Whitehead: Car suspension and handling, 4th
ed. SAE International Publishers (2004)

3. Kirpal Singh, Automobile Engineering, Volume 1. Standard Publishers (2000)

4. C. Mathews: Engineer’s data book. John Wiley and Sons Publishers (2011)

5. http://bajasae.net/content/2018-BAJA-RULES-FINAL-2017-08-30.pdf

6. LIST OF TABLES

Table 1: Categories of Common Tube Materials

Table 2: Steering Specifications
Table 3: Briggs & Stratton Engine Specifications

7. LIST OF PICTURES

Picture 1: Lincoln Electric 200c Welding Machine

Picture 2: Double-A-arms (Wishbone) suspension used in our baja
Picture 3: Rear suspension in our Baja
Picture 4: Endurance© Shock absorber
Picture 5: Tie Rods used in our vehicle
Picture 6: Side Views of the Stratton & Briggs Model 19L engine selected.
Picture 7: Engine mounted on top of the chain-and-sprocket system
Picture 8: Top Left: Master Cylinders; Top Right: Custom-made brake pedal and
its design rendering (above)
Picture 9: Discs and Callipers on each wheel of the Baja
Picture 10: Electrical Diagram of killer switches

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Mini-Baja 2018 – Design Report

APPENDIX

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1st Principal Stress
3rd Principal Stress