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Design and manufacturing for back axle for a new three-wheeled vehicle in tadpole configuration (forward trike), to compete in university gravity racing competition (called buggy).
Primary skills: CNC mill, manual mill, manual lathe, CAD, FEA, annodization, bending and shear stress calculations, DFM, fatigue analysis
Calculations and analysis of driver lines and vehicle dynamics to optimize axle width (track measurement), wheelbase, and stability along with considerations for driver comfort.
Test sample in preparation for annodizing entire assembly to protect the 7075 aluminum from galvanic corrosions caused by interaction with steel bolts.
Process chosen after a cost-strength analysis comparing steel to other metal alloys. 7075 Aluminum was chosen for its low density, high tensile strength, and relative affordability and availability.
DFM bracket iteration:
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