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M.E. 462 Capstone Design I.U.P.U.I. Spring 2007

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M.E. 462 Capstone Design I.U.P.U.I. Spring 2007

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    1. M.E. 462 Capstone Design I.U.P.U.I. Spring 2007 Bishop Steering: 1970 Lotus Europa Front Axle Re-design Aaron Emmons Phil Palmer Brad Holtsclaw Adam Spindler Adam Douglas

    4. Introduction Fixed Parameters Budget $3600 5” Ride Height 15” Wheels

    5. Design Specifications Development Customer Requirement (right) Top Three Requirements: Safety Minimizing Weight Braking from 200mph

    6. Engineering Specifications Ground Clearance of 5 inches Weight Minimization (parts made of aluminum) New Wheel (15” Audi Wheel) Overall width (outside wheel to outside wheel) to remain the same Overall width – Distance from frame to remain the same Braking Force to compensate for 1600lbs at 200+mph (Wilwood) Rotor size increased (surface area increase for larger braking friction)

    7. Engineering Specifications Cont. Hub size increased to compensate for 5-bolt Audi Wheel Deflection of bearings minimized Machining time increased due to no production line Factor of Safety increased (keep Jason safe at 200 mph)

    8. Competitive Benchmarks Minimization of Weight Maintain Safe Operation Conditions Stopping Vehicle going 200 M.P.H.+

    9. Literature / Patents

    14. Concept Evaluation Create Overall concepts Analyze Using Concept Outline Evaluate Decision Matrix

    16. Morphology

    20. Concept Outline

    22. Failure Modes Concept 1 Rotor heat warping Mechanical linkage for turning Stress/fatigue in linkages and ball joints Tapered bearings Degradation due to heat and friction Brake fluid w/ piston for stopping Leaks/ air pockets in brake lines Concept 2 Drums Heat warping the drum Foreign debris can enter the drum easily Heat Exchanger Fluid lines leaking Corrosion Mechanical linkage system for stopping Stress/fatigue in linkages and pin joints Knuckle w/ pin joints Limited number of degrees of freedom Cylindrical roller and thrust bearings Degradation due to heat and friction Pressurized fluid for turning Fluid line leaks

    24. Decision Matrix

    25. Load Distribution Lexus V8 mounted in the rear 60% rear 40% front 1600 lb force on each front wheel with a factor of safety = 5

    35. Conclusion Aluminum is a viable material for our design By using F.E.A. structural design of parts will withstand all applied forces with a safety factor greater than 5. At this time, 9 out of 12 Engineering Specifications have been met.

    37. Acknowledgements Dr. Hazim El-Mounayri Bishop Steering IUPUI Dept. of Mechanical Engineering

    38. Questions??

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