Engine Subframes

For the 2023-2024 Baja competition season, I designed our engine subframes. The subframes fix the engine in place, absorb vibrations from the engine to prevent fatigue failures in the frame, and must be able to last for at least forty hours without failing.

Summary

What:

Sets placement of engine
Absorbs vibrations from the engine
Must be as lightweight as possible while withstanding 40-hour lifespan

How:

Designed with SolidWorks
Matched geometry of chassis and engine
Analyzed cyclic and 3G landing loading from engine using Ansys

Result:

30% weight reduction from prior design
Passed analysis with factor of safety of 2.0
Did not fail

Skill: FEA & Iterative Design

Designing and analyzing the subframes was a crucial introduction to FEA and iterative design for me. Since the subframes experience cyclic loading, and one of their primary purposes is damping vibrations, it was critical that the subframes withstand the engine cyclic loading and not require replacement throughout our competition season. It was also important that the subframes be as light as possible, so that our team could meet our vehicle-level weight goals. To design strong and lightweight subframes, I employed iterative design methods to analyze the structure and reduce weight, ultimately creating subframes that were lighter than the prior year's and lasted all season.

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