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Davon Mukhar
Engineering Portfolio
Spring 2013
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: The frame and paneling of the
aluminum chassis was already complete when I
came into this project however it was not rigid
enough. To increase strength and rigidity for
better handling and maneuvering of the vehicle,
stringers began to be installed on the walls and
the floor of the chassis. These stringers needed
to be measure and filed down to fit along the
aluminum paneling sheets. Once fit to size
holes were drilled in the stringers and panels
and the stringers were installed with rivets.
More stringers were used in the area of the
chassis where force will be concentrated, such
as the suspension mounting area and the driver
compartment.
Documents:
Photographs
Assisted by:
Kevin Sale
Tyler
Chris Kent
1
Week 1 – Chassis Strengthening with
Stringers
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: This week we completed
installing the streamer by drilling and riveting
them on to the aluminum chassis. This was a
long a tedious process however it will
significantly aid the driver with maneuvering as
the stringers will increase the rigidity of the
finished vehicle.
As a new and younger member of
Racecar I began learning how to arc weld iron.
At this point I am perfecting creating a bead
and only tinkering with scrap pipe and
attempting to weld them to iron plates. As the
quarter goes on I plan to learn more and perfect
my welding techniques.
Documents:
Photographs
Assisted by:
Jose Ortis
Chris Kent
Tyler
Kevin
1
Week 2 – Learning to Arc Weld and Stringer
Completion
MAE 189: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: The chassis riveting is completed
and all the stringers are attached with rivets.
The next step is creating the suspension arms to
be attached to the body. The steel pipes needed
to be profiled so that they will fit together
respective with their orientation and then
welded together. I completed the profiling for
on set of suspension arms which consisted of
six steel pipes. In addition to this task I also
progressed in learning how to be come an
effective and elegant welder, I practiced
welding pipes to each other as well as to flat
surfaces. Lastly this week I was given the task
to create brackets to support the motor
controllers for Zeta. These brackets needed to
engineered from scratch so that the controllers’
panel can sit two inches above the areas they
will be mounted on the chassis .
Documents:
Photographs
Assisted by:
Chris Kent
1
Week 3 – Welding, Profiling, and Making
Brackets
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: This week I finished the control
mount for Zeta and drilled the hole for
mounting. This will mount the controllers that
will be connected to the electric motor for the
drive train. Now being both painted and clear
coated Zeta is ready to be assembled. My next
task is to design a way to mount and connect
steering potentiometer to the car’s computer.
This devices delivers information regarding the
turning of the wheels that will determine which
rear wheel will receive more power. This
increases control for the driver when turning
and cornering at high speeds. This device need
to be mounted to a fixed part of the steering
rack that will slide as the driver turns the
wheels. This will be tricky as there is very little
space to mount this delicate electronic
instrument.
Documents:
Photographs
Drawing
1
Week 4 – Control Mounts and Steering
Control
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description:
This week Zeta was being assembled. The
chassis was completed and the was painted with
a blue paint and clear coated for protection.
Now the car can be assembled with all the
parts needed for the car to operate. I installed
the steering rack which allowed me to then
determine the design of the mount fort the
steering potentiometer. A steering
potentiometer determine the degree to which
the front wheels turned and then powers the
rear wheels accordingly for maximum
handling. Another task that I worked on this
week was creating the hangers that would
mount the break calipers for the front wheels.
These uprights needed to be created from
scratch and made of steel to properly support
the break calipers.
Documents:
Photographs
Assisted by:
Chris Kent
Katie Leong
1
Week 5 – Install Steering Rack /
Potentiometer
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description:
This week Zeta was being assembled. The
chassis was completed and the was painted with
a blue paint and clear coated for protection.
Part of the assembly for the car was running the
brake lines and installing the calipers. The lines
need to be flared and then attached to the male
and female components in the caliper, pedals,
or connectors. The car has four brakes, all
hydraulic disc inside the wheel assemblies. We
used a metal brake line through out the car and
the rear axel and a soft line for the front wheels
that steer.
Documents:
Photographs
Assisted by:
Sharango Kundu
1
Week 6 – Brake System Assembly
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: This week I had to determine an
appropriate design for a chain guard. The chain
guard is required by Formula SAE as a safety
feature on all chain or belt drive train vehicles.
The guard for a chain must wrap the bottom
point of both the motor cog and axle cog, there
is also a certain thickness the steel must be. The
challenges with the initial design will be
bending thick steel into a perfect arc as well as
mounting the chain guard around the motors
and motor controls that are already mounted in
space. Another challenge was how to mount
and whether or not we would like to put more
holes into the rear part of the chassis since it
has already many part already mounted to it.
Documents:
Photographs
1
Week 7 Chain Guard
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: Now that I have developed a
design for a chain guard I needed to
manufacture it. I had to cut a piece of steel that
was approximately three feet long, four inches
wide, and quarter inch thing. To cut this I used
a table saw and after it was cut I buffed the
edges with an electric buffing wheel. Now that
the steel was ready to be bent I had to
determine how and how far to bend it. I
determined the radius I needed and decided it
was comparable to the larger wheel on the an
English wheel. The English wheel wasn’t
necessarily designed to bend metal but the
larger and small wheel were the perfect radius
to bend my steel around for the axle and motor
cogs. To mount the guard the controls were
removed and the guard was cut in half and then
welded to tabs that were drilled into the chassis.
Documents:
Photographs
1
Week 8 Chain Guard Manufacturing
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: After much contemplation and
discussion it was determined that Zeta was
going to get a slide potentiometer because there
was not enough time to order a custom radial
potentiometer to meet our specifications. We
needed to determine how to mount the
potentiometer to the car as well as how to
connected the slider to the steering rack. The
full travel of the potentiometer must be able to
be moved by the steering so that the controls
receive accurate information about what the car
is experiencing when its turning. We designed a
systems of steel bars to connect the
potentiometer in an accessible place and
connect to the steering.
Documents:
Photographs
1
Week 9 Steering Potentiometer
Assisted by:
Chris Kent
Jose Ortiz
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: This was the last week of race
car. As a second year in school and my first
quarter on the team I can with out a doubt say
that I learned a large amount of valuable
information about engineering. This last week
I worked a little less than usual because the
tasks that needed to be complete would not
have suited my experience, however there was
still some I could do. The aluminum frame,
Gamma Prime chassis needed some steel
suspension mounts made. I drew the outline
and then cut out the middle of the blocks and
then used the grinder to shape them correctly.
Documents:
Photographs
Assisted by:
Mason Sattes
1
Week 10 Gamma Prime Suspension Mounts
Spring 2014
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: Part of the design for the Baja car’s drive train will be gearing the engine with a transmission. For this we have the option between a CVT (continuously variable transmission), or a geared transmission from a motorcycle or ATV. The factors that play in to determining which one we will use will be the weight of the components and the functionality. Ideally we would like to have a reverse drive gearing but this does not exist on most accessible CVTs nor motorcycle transmissions (which are alone heavier than desired) and mainly found on larger hunting ATVs. In addition to transmission drive train work, this week I was also working practice Solid Works. As an Aerospace major Solid Works is not in my required curriculum so I have to independently learn how to use this software. Documents: Photographs Assisted by: ----
13
Week 1 – Transmission and Solid Works
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: Over the weekend the Beta car that is being worked on by my team for the energy invitational, hit a pole and bent the left A-arm on the front wheel; thus a new one had to be made. We decided that the arm did not have to be bent like originally so we decided to make it triangular instead to avoid having to bend it. Also this week we decided that a FNR (forward neutral reverse) CVT would be the best option for the Baja vehicle. We decided that the CVT will: prevent stalling, and thus restarting the vehicle will not be an issue. As well as being easier to operate and install, be relatively lighter, and have a reverse driving mode which is necessary incase we need to rock the vehicle to get it unstuck in competition. Documents: Photographs Assisted by: Max Venaas
Week 2 – A-Arm Replacement and CVT
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: We decided to experiment with our TIG welding abilities and try it out on the newly designed A-Arm for Beta. After this we installed it on the chassis and set the toe of the upright. Beta was taking to a track day this weekend to due further adjustments on the suspension and wheel angle to prepare it for the energy invitational. In addition after Zeta’s crash it needed to sanded and re-painted. I sanded it to take the pain and finish off before repairs and repainting. Documents: Photographs Assisted by: Max Venaas
15
Week 3 – Install A-Arm for Beta
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: This first step analyzing the strength of a chassis design after completing an FEA will be to create a half scale model that can be further analyzed. This half scale model will be created with the same mild steel that the full scale will be built however the tubing wall thickness will be thinner and the diameter will half of the full scale. The requirement for tube diameter under the Mini Baja specifications is 1in. and we are going to conform with this minimum spec. The minimum wall thickness required is .035in. however we are planning to use .06in. for safety and strength. The roll hoop and cage however, must be a thicker walled tube of .12in. All tubing material are being purchase and priced from Industrial Metal Supply Co. in Irvine. Documents: Photographs Mini Baja Rules Assisted by: Max Venaas 16
Week 4 – Half Scale Chassis Material
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: This week in race a car the Baja, Green Team, was preparing Beta for the Energy Invitational on May 10th. The first concern was Beta’s tires, they needed to rotate and flipped on the wheels. This will prevent the threads from being exposed and prevent a blowout. In addition the brake light as well as the tachometer for the motor needed to be re-wired. The brake light is a requirement for all vehicles entering the Energy Invitational . The rpm reader will allow us to better manage the fuel consumption as we can determine how much energy the engine is consuming. Documents: Photographs Assisted by: Baja Race Car Team
17
Week 5 – Energy Invitational Pre-Lim
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: This week was the Energy Invitational. This event is hosted by UCI and it is a challenge of efficiency. Each team is given a dollar’s equivalence worth of fuel to see who can go the furthest while managing time. My team was racing the UCI car, Beta. To improve Beta’s performance I decided to create a nose cone that will make the chassis more streamlined thus increasing aerodynamics and efficiency, without this measure Beta would not stand much of chance compared to electric vehicles. After the competition we realized while the modifications were beneficial, because we did not precisely know how Beta was going to improve we were not able to make the most precise energy calculations to maximize our points. As a result Beta placed second, however we learned a lot on managing a race team. Documents: Photographs Assisted by: Max Venaas Beta Race Car Team
18
Week 6 – Energy Invitational
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: For SAE Baja the power plant for the vehicle are pre-determined and actually given to us by the SAE competition. The motors are not allowed to physically modified but some additions are acceptable. With this we have to choose a transmission very carefully so that it will work the best possible with the engine. In addition to having a transmission that is well suited for the engine it must have certain functions for the events in the competitions. It must be light and compact as well as having a forward, neutral and reverse drive modes. Having reverse will allow us to get unstuck, without it we could be disqualified if we get stuck during an event. One thing that has to be assessed is whether or not we are going to need high and low drive modes which can change the amount of torque delivered to the wheels. Documents: Photographs
19
Week 7 – Polaris CVT Specifications
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: This week we created goals and deadlines for the mini baja car we are designing. Our goal is to attempt to complete at least one half scale model so that we can analyze the possible characteristics of a full scale chassis. In addition, this week we completed a FEA on the chassis in SolidWorks to compare the structural strength of each design. I am still determining and attempting to obtain specs and a proper model transmission from Polaris. Most of the information we need is proprietary and is making this difficult. Lastly this week we prepared Beta for storage and moved it into the cargo container for the summer. Documents: Photographs Assisted By Max Venaas
20
Week 8 –Beta Storage and Baja Drivetrain
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: The final goal of the Baja team this quarter is to create a full model of the baja car to be manufactured in the fall. This requires parts to be designed or found online and pieced together. I am still trying to find a proper model and specification for a Polaris FNR CVT. This maybe replaced in the initial model with the currently existing Comet CVT from the Beta car, which may be also taken apart for testing and analysis before fabrication on the new vehicle is started. On a side note the FEA completed on our chassis model has shown an undesirable result as our model seems to be failing at certain points. At this point we think it is because of human error when setting up the FEA rather than a bad design, but we cannot be sure either way. Documents: Photographs Assisted by: Matt Miller Max Venaas
21
Week 9 – Baja Model
MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar Description: In this final week the goal is to complete piecing together the Baja car model in SolidWorks. We are presenting a poster at the spring design review and really would like to have a final model to go along with the poster. Most of the parts have been designed or found in the archives and the last major step is to set the suspension and steering geometries on the vehicle. We are planning to use an on-board rocker system. This will allow to keep the shocks within the chassis rather that having them fully exposed on the sides. This can result in a smaller travel required of each individual shock which will cut down on weight and could lower the center of gravity for the vehicle. Documents: Photographs Assisted by: Matt Miller Max Venaas
22
Week 10 – Finish SolidWorks Model
Fall 2014
MAE 189: Racecar Design and Manufacturing
Week 1 – Cleaning Engine Lab and Driveline
Name: Davon Mukhar Description: This quarter I have been assigned as one of the team leads on the Baja car. My sub-system lead will be for drive line and driver interface as well and Max will have chassis and suspension. To begin the year we needed to clean the engine lab and reorganize it to allow is to be more efficient workers rather than wasting time hunting for equipment. I also had to learn about driveline and driver interface. Last quarter we left off and decided to use a CVT with ideally a high, low, reverse, and neutral driving mode. Obtaining this will be more tricky because many ohv vendors make their own. In addition to obtaining components we also need to determnine what types we need, for example a solid rear drive axle or differential. Documents: Photos
Assisted by: Max Venaas 24
MAE 189: Racecar Design and Manufacturing
Week 2 – Drivetrain Parts
Name: Davon Mukhar Description: The Baja car will most likely have a wish bone type axle in the rear instead of a solid axle. This means we will need a CV joint to attached to half shafts. The main problem with a CV is that most common maximum angle that can be achieved is 20 degrees which may be tricky to use while trying to achieve 12 inches of suspension travel. However after researching other baja groups and researching manufacturers I have founds a cv joint that will allow 40 degrees of movement which may allow us to get 12 inches of suspension travel. Documents: Photos (see attached), Docs on Drive
Assisted by: Baja XV Drivetrain Team
25
MAE 189: Racecar Design and Manufacturing
Week 3 – Vehicle Weight and Track Day
Name: Davon Mukhar Description: This week the driver interface team, drive train team and I determined the weight on certain components of the vehicle. Estimating an approximate weight will allow us to determine the theoretical center of gravity and thus design the suspension geometry more accurately. Also this week was the Baja XV team’s first track day. I design a 1447 ft course that included hair pins, straight-aways, and slalomed curves for the purpose of driver development. We used this day to show the team what race day would be like and what duties are conducted by the host race team, such as timing, and flag work. Documents: Photos, Driver Times Assisted by: Max Venaas and Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 4 – Steering Geometry and CVT Torque
Name: Davon Mukhar Description: This week the Baja XV Team has nearly finalized a suspension geometry that will allow fabrication of half scale chassis models to be fabricated. With this a steering geometry can be designed that will allow the steering linkages to be low weight and in a geometry that is compact and out of the way of the driver and other components. Documents: Photos (see attached)
Assisted by: Zeta Battery Box Team, Baja XV Driveline Team
27
MAE 189: Racecar Design and Manufacturing
Week 5 – Half Scale Model and Steering
Name: Davon Mukhar Description: This week manufacturing of the half scale model began. Our goal is that we will have two complete half scale models that we can do testing on this fallowing week. In addition, we are going to fabricate a half scale steering set geometry that we can analyze to compare different set ups. For the driveline team we have decided that we are going to fabricate a differential in house. This differential will gear down in a 4:1 ratio our transmission output to our wheels in addition to having a reverse gear train that can be selected by the driver when the vehicle is stopped. Documents: Photos (differential: hypothetical set up)
Assisted by: Baja XV Human Interface Team, Jeff Beasley
MAE 189: Racecar Design and Manufacturing
Week 6 – Half Scale and Steering
Name: Davon Mukhar Description: This week in the Baja XV team we were beginning the fabrication of our second chassis design half scale. This half scale will most likely be our final design because it is rules compliant where our first half scale design would infract on the clearance between chassis and driver’s head rule. In addition to the half scale chassis, working with JJ, we are designing a proper steering geometry that will limit the amount of bump steer. The problem we are having though is the clearance between the tie rods and the a-arms. We will be able to properly design this geometry as well as the design of the uprights when the suspension team has finalized their suspension geometry. Documents: Photos, Chassis #2 Drawing
Assisted by: Baja XV Chassis Team, JJ Javellana
MAE 189: Racecar Design and Manufacturing
Week 7 – Second Half Scale Fabrication
Name: Davon Mukhar Description: The goal for this week is to complete the second half scale model, which unlike the first design is rules compliant. Through the process of fabricating this model we will be able to develop a technique of fabrication that we will apply when building the full scale chassis, our goal to have completed by the end of the quarter. When the half scale is complete we can do further structural analysis as well as part geometry, set up half scale assemblies that can also be studied dynamically such as steering and suspension. Documents: Photos
Assisted by: Chassis Team
MAE 189: Racecar Design and Manufacturing
Week 8 – Finish Half Scale Begin Full Chassis
Name: Davon Mukhar Description: This week we have finished the half scale model and have decided to begin fabrication of our full scale chassis. The full scale will be fabricated with the use of wooden jigs that will insure that the geometry is correct during welding. We have decided to use our beta chassis design as this design is rules compliant and caters to the goals we have for our vehicle. Documents: Photos
Assisted by: Baja XV Chassis Team
MAE 189: Racecar Design and Manufacturing
Week 9 – Fabricate Full Scale
Name: Davon Mukhar Description: This week we are preparing for the Fall 2014 Design Review. Our goal as a team is to have a completed chassis that we can display. The fabrication process is going relatively smoothly because of the amount of people and delegating tasks accordingly so that every one is contributing to the goal at hand. We have all the members cut to length and the remaining members only need to be profiled and welded to the chassis which we plan to have done by Friday. Documents: Photos (see attached) Assisted by: Beta XV Team, Curtis
MAE 189: Racecar Design and Manufacturing
Week 10 – Finishing Chassis and Design Review
Name: Davon Mukhar Description: This week we were putting the final touches on full scale before the fall design review. We inserted pvc members where we wanted to display the possibility of adding other members to chassis but had not yet. We hope to being ordering the components for drivetrain and user interface gradually before the next quarter and early winter quarter 2015. Documents: Photos (Calculation Assisted by: Baja XV Team, Max Venaas
Winter 2015
MAE 189: Racecar Design and Manufacturing
Week 1 – Complete Chassis
Name: Davon Mukhar Description: The first task of the quarter for the Baja XV was to complete the chassis. With an updated FEA on modified chassis with some members removed, we have determined that the chassis is of a comparable strength a no significant change to chassis’ integrity was affected. With this we completed the full scale chassis. I have begun a preliminary design for a steering system by taking calculations determined between JJ Javellana, who is not longer in the course, and myself from last quarter. At this point the suspension team will complete the suspension design and mounting tabs will be attached to the chassis Documents: Photos
Assisted by: Max Venaa, Nick Borrelli, Ryan Roach
MAE 189: Racecar Design and Manufacturing
Week 2 – Steering Design and Track Day
Name: Davon Mukhar Description: This week in race car I began initial design of the steering system. We want a steering setup that will allow for the most maneuverability as well as diminish the amount of bump steer occurrence. This can be accomplished with a simple design, however the final design we rely on the orientation of the suspension, uprights, and A – arms. In addition this week I built a new ramp for the container where we store some vehicles that is 17 inches off of the ground. Documents: Photos, steering design calculations Assisted by: Kyle Taggart and Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 3 – Steering and Breaking Calculations
Name: Davon Mukhar Description: To determine an appropriate point to begin analyzing what kind of breaks, steering wheel, and rack and pinion we need, we analyzed our old Baja car Beta. We determined that the Beta is 1.25 turn lock to lock and therefore our initial goal to have our steering 1.5 lock to lock will allow for more precision, and being that we have a larger cockpit, it will allow for more space to turn the wheel. In addition we made calculation to determine the breaking force on the Beta car. We determined that with the rear breaks disconnected that we could stop in 20 feet at a rate of 20mph. Documents: Break Testing Data, Photos
Assisted by: Jeff Beasley, Patrick Kim
MAE 189: Racecar Design and Manufacturing
Week 4 – Steering and Seat Design
Name: Davon Mukhar Description: This week in race car engineering I began modeling the steering design as well as seat ergonomics in Solid Works. We have determined that an additional member will be needed to be attacked to the chassis so that the seat and seat belts can be properly mounted. The steering rack will be placed in the front control box and aligned in line with edges of the box to reduce bump steer. Documents: Photos, SolidWorkds Models Assisted by: Patrick Kim, Frank Cai
MAE 189: Racecar Design and Manufacturing
Week 5 – Steering Column Design and Uprights
Name: Davon Mukhar Description: This week in racecar engineering we ordered the rack and pinion assembly for our steering as well as a steering wheel and seat. The rack will give us 1.5 turns lock to lock and we wanted a felt textured 10 inch steering while with 1 inch diameter around for suitable grip in wet or muddy conditions. In addition preliminary design has begun on the steering column. We would like a steering column that is out of the way of the drivers feet so that the driver has the option of using one foot or both to drive with. If the column ran directly between the legs this would not be possible. Documents: CAD Files
Assisted by: Patrick Kim, Frank Cai
MAE 189: Racecar Design and Manufacturing
Week 6 – Finalize Designs and Gantt Chart
Name: Davon Mukhar Description: This week we created our team Gantt chart that we will go off for the rest of the quarter and next quarter. We determined the hard deadlines for design where we would stop designing and beginning fabricating what we have. As a first year team we need to just get a car rolling so it can be analyzed. Any unfinished design can be goals for the next generation vehicle. Documents: Gant Chary, Photos
Assisted by: Max Venaas and Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 7 – Prep Engine Lab for Assembly
Name: Davon Mukhar Description: Up to this point in the project most of our work has been in the weld lab, but with the chassis complete, we have began ordering parts and began to prepare for assembly of the vehicle. As a first generation prototype are goal is to obtain most of our part off of the shelf so we can at least get a car running. This will allow future iterations of an off road Baja car to improve upon our initial designs. In addition we determined an angle of 25 degrees from the normal for out seat angle which will allow taller drivers to fit in the vehicle. Documents: Photos, Rules’ Diagram
Assisted by: Frank Cai, Max Venaas
MAE 189: Racecar Design and Manufacturing
Week 8 – Pedal Assembly and Light Sensor
Name: Davon Mukhar Description: With an appropriate master cylinder chosen that would deliver an adequate amount of pressure a pedal assembly needed to designed. There are many off the shelf options for pedal assemblies. The next step, will be to determine a strength needed for a pivot point for the pedal. A person can deliver between 200lb – 300lb of brake pedal force, however with an adrenaline rush this can double. Therefore a moment point that can support a 500lb – 600lb shear force about a moment arm of 10in. – 12in. In addition a brake light sensor must be attached to each of the two brake circuit systems to activate a brake light for the vehicle. Documents: Photos, Drawing
MAE 189: Racecar Design and Manufacturing
Week 9 – Steering Mounting and Column
Name: Davon Mukhar Description: One of the design goals was to have an adjustable steering mount that will allow the steering wheel to adjust to shorter and taller drivers. The adjustable column will allow a variety of angles tilting the steering wheel closer or further from the driver. In addition, preliminary design was determined for the steering wheel mounting member, that will allow for more clearance for the driver’s legs when they enter and exit the vehicle. Documents: Photos, Model
MAE 189: Racecar Design and Manufacturing
Week 10 – Mounting Points and Design Review
Name: Davon Mukhar Description: This week we were expecting to receive parts that have been ordered throughout the quarter. This would allow us to have a rolling vehicle at the design review. However, because of shipping logistics were not able to achieve this. Instead we were able to mount tabs and install body panels and engine mounting points. We also mounted suspension tab and A-arms and steering rack mounting points. By the first week of next quarter we are expecting to have a fully rolling vehicle with another week lead time to get it to initial shakedown. Documents: Photos
Assisted by: Baja XV Team
Spring 2015
MAE 189: Racecar Design and Manufacturing
Week 1 – Sourcing Parts and Seat Tabs
Name: Davon Mukhar Description: The initial goal for this quarter is to make sure that all the parts required get ordered by the second week of school to ensure that we receive them with enough time to assembly the vehicle. The competition is week nine and our goal is to have a running car week six so we have an adequate amount of time for testing, tuning, and driver development. Most parts for user face have been sourced. The seat tabs have been mounted in the appropriate positions that comply with the rules. Documents: Photos
Assisted by: Max Venaas
MAE 189: Racecar Design and Manufacturing
Week 2 – Steering Column and Tie Rods
Name: Davon Mukhar Description: The final design for the steering set up has been determined. We are going to purchase an adjustable tilt steering column as well as fabricate a telescopic steering shaft. This will allot for adjustments to fit drivers comfortably. Our developed telescopic set up will include multiple length options where the shaft can be pinned and clamped for a static shaft feel, and adjusted as necessary. In addition to limit the amount of bump steer a tie rod length of 17 inches has been determined. These will meet the steering rack that has been extended 3.6 inches on either side with a clevis so that the pivot point will align with the A-arm pivot point. Doing this will cause the A-arms and steering tie rods to have the same rate of change of angle when the suspension cycles.
Assisted by: Vanessa Zin
MAE 189: Racecar Design and Manufacturing
Week 3 – Mounting Steering Rack
Name: Davon Mukhar Description: This week I determined the angle the steering tie rods would experience as the suspension cycles from maximum compression to maximum extension. As a result I needed a super swivel or high angle ball joint rod end for the tie rods. After the angle was determined, I determined a location where interference between the steering at full lock and the A-arms would not occur. We mounted the steering rack using four mounting tabs. Using four mounting tabs will give the strength and rigidity required for the steering forces and at an angle such that a U-joint would effectively link the steering shaft to the rack. Documents: Photos, Calculations
Assisted by: Ronny Gutierrez, Frank Cai
MAE 189: Racecar Design and Manufacturing
Week 4 – Steering/Vehicle Assembly
Name: Davon Mukhar Description: The steering system has been design and with components received we began fabrication. We used a DOM steel lower shaft for strength and rigidity for the component directly mounted to spline pin. For the upper shaft we used ¼ inch thick aluminum alloy which is much lighter than steel but will also provide the stiffness required from driver steering input. The goal for the entire vehicle will to have it running by the end of this week. Documents: Photos
Assisted by: Venessa Zin
MAE 189: Racecar Design and Manufacturing
Week 5 – Rear End Fabrication
Name: Davon Mukhar Description: The final design for out chain driven rear end was finalized. Components that would link our half shafts to a solid rear axle where the chain sprocket and brake rotor will be mounted need to be fabricated. I machined the sleeves that will attach the half shaft splines to the solid center axle. Documents: Photos
Assisted by: Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 6 – Human Interface Components
Name: Davon Mukhar Description: Our new goal for the vehicle to have every mounting welded and in operating condition by the beginning of week 8 so that we can test for a week and tune suspension. I had to determine final human interface components. In addition the mounting plate for the engine and FNR gear box were completed and mounting point were developed for those as well. Documents: Photos
Assisted by: Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 7 – Redo Steering Mount Location
Name: Davon Mukhar Description: After the steering mount points were tacked into place we decided to adjust the position of the mounts that changed the angle of the steering shaft. This allowed for a better driver ergonomics when driving the vehicle. Documents: Photos
Assisted by: Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 8 – Vehicle Testing
Name: Davon Mukhar Description: With the vehicle drive train assembled we were able to do some initial testing. We testing the vehicle four wheel braking on asphalt as well as on dirt that we will be required to perform to pass technical inspection. We also tested the vehicle in a small dirt course that included an incline and an off camber turn where we could asses the vehicle dynamics. From this analysis we determined that we needed to adjust the pressure in our front and rear shocks. Documents: Photos
Assisted by: Ronny Gutierrez, Max Venaas
MAE 189: Racecar Design and Manufacturing
Week 9 – Baja SAE Oregon
Name: Davon Mukhar Description: We traveled to 17 hours to Portland to check in for the Baja SAE Oregon. There were 100 teams from across the country, Canada, and South America. We were able to pass tech and compete in every dynamic event as well as the endurance race. Overall we achieved our goal as a team and placed quite respectably for a first year team. Documents: Photos
Assisted by: Baja XV Team
MAE 189: Racecar Design and Manufacturing
Week 10 – Year End Wrap Up
Name: Davon Mukhar Description: Post competition for the Baja XV team included cleaning the vehicle as well as fixing some components that were damaged in competition. At the end of the week there was a track day senior commencement ceremony where the new vehicle for the year were displayed. Documents: Photos
Assisted by: Entire Racecar Team