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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
DFM and FEA informed bracket iteration:
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.
Full assembly anodization
Annodization tests involving internal threads continuously failed--the steel bolt continued to scrape and degrade the coating. Zinc-chromate plated bolts and anti-seize lubricant with aluminum and graphite additives were uses in conjunction with anoodization to best protect the parts.
Calculations and analysis of driver lines and vehicle dynamics to optimize axle width (track measurement), wheelbase, and stability along with considerations for driver comfort.
Huston, Graves, and Johnson. “Three Wheeled Vehicle Dynamics.”
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