Attachment # 00008384 - MEGN_481_Fall_2015_Final_R3_Version_2.docx
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MEGN 481Fall 2015Take Home FinalDue December 8 at the beginning of class unless prior arrangements were made with me via emailPart 1- Chassis Component Design.You have been tasked with re-designing a triangulated 4-link rear suspension system for a GM muscle car. These suspension systems are sometimes called “canted 4-link” as well triangulated 4-link. The original engineer at your company was hit by the beer delivery truck while transporting all pertinent documents relating to an existing product. Unfortunately the accident was followed by a James Bond style explosion, so not only did the engineer expire, all pertinent documents expired with him. As such, the only information you have while attempting to redesign the product is from the companies’ online catalogue. Specifically, you must redesign all four separate “link” assemblies and the mounting hardware in the Chris Alston’s Chasisworks canted tubular pivot-ball 4-link rear suspension system for the 1st generation Camaro (P/N 5804-F10, https://www.cachassisworks.com/p-1299-camaro-67-69-firebird-67-69-gm-f-body-g-link-pivot-coil-over-suspension.aspx). The assembly is shown in figure 1 and the components to be designed/engineered are shown in Figure 2. The car of interest weighs 3200 lbf and has a 60%/40% weight distribution front/rear, 50%/50% weight distribution left/right and a center of gravity that is 21” up from the ground. The rear is supported by the VAS 11111-515 coil-over shock and VAS 21-12200 springs. The front coil-over shock is the VAS 11111-425 in conjunction with the VAS 21-09600 spring. The shocks and springs can also be found on Chris Alston’s website as well.Figure 1: Chris Alston’s Chassisworks Canted 4-link suspension kit for a first-generation Camaro Figure 2 (left): Typical upper links, lower links and mounting hardware.Figure 3: (right) system components for the generic 4-link suspension system (P/N 78F313)…a good place to get info. Everything you need for this task can be retrieved via Chris Alston’s website. Specifically, I would start with the url’s below, look through all of the images, related products, and every single instruction and tech info .pdf.https://www.cachassisworks.com/p-1299-camaro-67-69-firebird-67-69-gm-f-body-g-link-pivot-coil-over-suspension.aspxhttps://www.cachassisworks.com/p-1559-canted-tubular-pivot-ball-4-link-rear-clip-4x2-frame-rails.aspxThe car is intended to have a powertrain and suspension capable of competing with the Ariel Atom 3 in acceleration from 0 mph to 100 mph, braking from 70 mph to 0 mph characteristics. This will likely be the worst case scenario loading situation. The following specs on the Atom 3 were pulled from the Car and Driver website (http://www.caranddriver.com/reviews/ariel-atom-3-specialty-file)Zero to 60 mph: 2.9 sec Zero to 100 mph: 6.4 sec Zero to 130 mph: 12.6 sec Street start, 5-60 mph: 3.4 sec Standing ¼-mile: 11.2 sec @ 125 mph Top speed (governor limited): 155 mph Braking, 70-0 mph: 158 ft Roadholding, 300-ft-dia skidpad: 1.12 gThe car must also be able to be road driven. Therefor we will assume that a pothole imparts a 2.5” vertical displacement impulse (model as 2.5” down followed by 2.5” up) is applied to the tires every ¼ mile and the suspension components must have an infinite life (design for 300,000 miles in this case).Your deliverable for this portion of the exam must include:The design for the upper suspension link assembly (the short one).Provide a drawing for the upper suspension link (the 4-link system will consist of two of these)The engineering analysis for the upper suspension link assemblyThe assembly must include the link mounting provisions (bearings of some sort), and the “connector” between the mounting provisions (rod or tube of some sort), and mounting bolts, minimum.Engineering analysis must consist of static, dynamic, and any other analysis you deem necessary for all of the components in the upper suspension link assembly that you are specifying (rod/tube?, bearings?, Threads to attach bearings to rod/tube?, mounting bolts?)A complete BoM for the upper suspension link assembly and it’s mounting provisions (bolts).Specify all materials, part numbers of off-the-shelf components, bolt callouts with grades, etc.Repeat the above three bullet points for the lower link assembly (the long one)In order to help me with your grading (and certainly not because I want to wipe your rear ends), I am providing you with a coloring book template for your deliverables. I will grade the coloring book only…stay inside of the lines. Use pages 4-9 as cover pages and turn in your work appended to the document.Some helpful bits of information:When the rear springs are installed on the shocks they have a 1” preload distance (Yinitial=1”)When the front springs are installed on the shocks they have a 1/2” preload distance (Yinitial=1/2”)You will likely need to scale/measure from some of the drawings on the website.When viewed from the side, the lower link of the 4 link system should be assumed to be horizontal.When viewed from the passenger side, the upper link should be assumed to be at 10° from horizontal with the front lower than the rear.Though not exactly the case, you can assume that the rear shocks are mounted on the rear differential housing directly behind where the lower link mounts to the rear end housing. You can assume that this distance is 43”.The cars rear roll center is 3” below the cars center of massFBD (plural perhaps)- sketches:Boundary Conditions and Loading Conditions:Boundary Conditions (words):Static Loading Conditions (words):Dynamic loading conditions (words):Design DWG (plural perhaps):BoMCalculations to support all findings (append necessary support documents):Part 2- Spring Design.You are using the VAS 21-12200 spring at the rear of this vehicle. Given the dynamic loading described on page 2, the cars weight in conjunction with both the spring and shocks physical constraints (spring travel, shock travel, etc.), determine the number of pothole impulses the spring can withstand before it fails.
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