Alt Fuel Group, SrDesign, 1

Alternative Fuel GroupFRAME

Justin BaharKyle BallDan KesslerJustin Muesel

Alt Fuel Group, SrDesign, 2

Alternative Fuel GroupComponent Selection

FinalDesign

Component & FEA

Material Selection

Frame Selection

Alt Fuel Group, SrDesign, 3

Alternative Fuel GroupSteel vs. Aluminum

• Environment– Steel is recycled easier

• Fatigue– Steel has an endurance limit, Aluminum does not– Steel infinitely cycled w/o failure when kept under

endurance limit• Weldability

– Steel easier to weld• Hardness

– Aluminum’s hardness is less than Steel– Surface quality hard to maintain for Aluminum

http://ussautomotive.com/auto/steelvsal/basicfacts.htm

Alt Fuel Group, SrDesign, 4

Alternative Fuel Group

Materials Cost/ft. Weight Machinability Strength Availability

Round Lb/cuft. (psi)

4130 Alloy Steel $4.70 .284 70% 75,000 X

1026 Carbon Steel $2.69 .284 75% 60,200 X

1045 $5.28 .283 55% 75,000 X

Al 6061 $9.77 .0975 50% 35,000 X

Square

1008/1015 Carbon Steel

$2.31 .284 55% 24,700 X

4130 Alloy Steel $7.81 .284 70% 75,000 X

Al Alloy 6061 $4.03 .0975 50% 35,000 X

-Al Machinability based on 0-100 Scale of Al Alloys- Steel Machinability based on 100% machinability for AISI 1212

Charting the Material

Alt Fuel Group, SrDesign, 5

Alternative Fuel GroupTechnically Supported

• Idea: use 1” steel tubing– Either 4130 or 1026– Strength, Machinability, Cost

• Plan of Action– FEA analysis to see if 1” tubing is sufficient– Use possible mock up

• Check clearances• Field of vision

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Alternative Fuel GroupForce Placement

• Forces placed to represent simple dynamic loading

• Pinned Boundary conditions

290lbs

40lbs

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Alternative Fuel Group

ANSI 4130

ANSI 1026

Material Choices

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Alternative Fuel GroupFrame Ideas/Decisions

• Steel tube – 1” O.D. wall thickness 0.13

• 4130 or 1026 • Minimize welds and parts

– Less pieces = better– Halo Idea

• Surface treatment– Powder coat or paint

Alt Fuel Group, SrDesign, 9

Alternative Fuel GroupSafety of Design

• Bends or Corners?• Sufficient Frontal Space

– 60” for operator to enter/exit vehicle• Reinforced Welds

– Seam weld, not stitch– Gussets at several joints

• Consider side impact @ later time

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Alternative Fuel GroupSafety

• Possible rollover• Physical contact

across top part of frame

Possible contact points

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Alternative Fuel Group

Frame: Curved vs. Boxed

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Alternative Fuel GroupFunctionality

• Specs– Vehicle must fit inside 3’x6’x6’ “box”– Vehicle must fit a 95th percentile person

• 6’2” and 255lbs.– Provide for 2ft3 and 30lbs. of storage

Alt Fuel Group, SrDesign, 13

Alternative Fuel GroupOur Functionality

• Alt. Fuel Vehicle: 2.3’x5.1’x5.8’ - meets spec.• 95th percentile male fits• 3ft3 of storage

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Alternative Fuel GroupFrame Joints FMEA

-Examine Weld Joints

-suspension-to-frame

-frame-to-frame

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Alternative Fuel GroupFMEA: Steel Tube Frame

Possible Failures• corrosion/rust• fatigue • improper welding technique• excessive loading • improper material selection• improper use of FEA

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Alternative Fuel GroupRisk Priority Number: 450

SEV: 10

OCC: 5

DET: 9

• loss of control of the vehicle• injury of the passenger

• inexperience in technique of welder

• FEA used to prevent failure

• Minimal chance to detect

Alt Fuel Group, SrDesign, 17

Alternative Fuel GroupFMEA: Mounting Plates

Possible Failures• Overloading • Corrosion• Fatigue• Insufficient welds

b/n plate and frame• Improper use of

FEA / hand calculations

Alt Fuel Group, SrDesign, 18

Alternative Fuel GroupRisk Priority Number 384

• SEV: 8

• OCC: 6

• DET: 8

• Barely works, bad performance

• Some chance of occurrence

• Little prevention and hard to detect

Alt Fuel Group, SrDesign, 19

Alternative Fuel GroupQuestions?