Front Suspension

Greg Habiak, Nicole Simon, Joe Vuto

Bill of MaterialsNo. Part Source Part No. QTY Weight per

PartCost per Part

(Retail)Total

Weight Total Cost

1 21x7-10 M933 Tire (Razr2 Front) Tires Unlimited T682400 2 10 $114.05 20 $228.102 Douglas DWT Red Label Wheel Rocky Mountain ATV 1087620028 2 4.9 $77.00 9.8 $154.00

3 2011 Yamaha Raptor 125 Steering Knuckle/Hub Assembly MotoSports On next slide 2 4.6 - 9.2 $1,158.58

4 Top A-arms McMaster-Carr 9056K762 2 1.0667 $25.07 2.1334 $50.145 Bottom A-Arms McMaster-Carr 9056K762 2 1.5748 $25.07 3.1496 $50.146 5" Pro Shocks Speedway Motors 582ASB510B 2 2.319 $178.99 4.638 $357.987 Hyperco Coil-Over Racing Springs Speedway Motors 44414-100 2 2.5 $59.99 5 $119.988 Steering Arms Chassis Shop 60-1-083 2 0.3623 16.4125 0.7246 $32.839 Steering Arm Connection McMaster-Carr 8910K653 2 0.7984 $4.80 1.5968 $9.60

10 Chromoly Steering Column Moore Parts AC425010-3 1 1 $34.00 1 $34.0011 Universal Joint and Boot Moore Parts AC425261-1 1 0.75 $40.00 0.75 $40.0012 Steering Column Bearing Moore Parts AC425014 1 0.25 $18.00 0.25 $18.0013 Aluminum Butterfly Steering Wheel BMI Karts 600680 1 1.5 $44.99 1.5 $44.9914 Rack and Pinion Chassis Shop 1 2.74 $327.95 2.74 $327.9515 Fixture for Rack and Pinion McMaster-Carr 6527K134 1 3.05 $10.66 3.05 $10.6616 Tabs McMaster-Carr 8910K395 20 0.1 $0.31 2 $6.2017 5/8" Ball joints McMaster-Carr 6960T21 4 0.47 $26.18 1.88 $104.7218 5/8" Threaded Aluminum Weld Bungs Midwest Control Products Corp. WTFA-10R-0.995 4 0.33 $4.78 1.32 $19.1219 1/2" Bolt/Nut McMaster-Carr 4 0.2 $0.20 0.8 $0.8020 1/2" Ball joints McMaster-Carr 60645K852 8 0.37 $7.28 2.96 $58.2421 1/2" Threaded Aluminum Weld Bungs Midwest Control Products Corp. WTFA-8R-0.994 8 0.33 $4.69 2.64 $37.5222 3/8" Bolt/Nut McMaster-Carr 8 0.15 $0.30 1.2 $2.4023 3/8" Ball joints McMaster-Carr 6064K832 4 0.25 $4.59 1 $18.3624 3/8" Threaded Aluminum Weld Bungs Midwest Control Products Corp. WTFA-6R-0.795 4 0.33 $6.97 1.32 $27.8825 5/16" Bolt/Nut McMaster-Carr 4 0.13 $0.35 0.52 $1.40

Total 81.17 $2,914

2011 Yamaha Raptor 125 Steering Knuckle/Hub Assembly

Part Part No. Qty Retail Price per Part Total Cost

Hub Assembly

Hub, Front 3GD-25111-20-00 2 $222.55 $445.10 Bolt, Serration 90114-10006-00 4 $3.84 $15.36 Spacer, Bearing 1UY-25117-00-00 2 $14.84 $29.68

Bearing 93306-00446-00 2 $21.44 $42.88 Bearing 93306-20231-00 2 $21.95 $43.90 Oil Seal 93105-26026-00 2 $9.34 $18.68 Oil Seal 93102-22216-00 2 $7.14 $14.28

Nut, Flange 95704-10500-00 8 $4.19 $33.52 Collar 90387-150R1-00 2 $6.04 $12.08

Washer, Plate 90201-14220-00 2 $3.25 $6.50 Nut, Castle 90171-14002-00 2 $5.45 $10.90 Pin, Cotter 91490-30030-00 2 $3.25 $6.50

Cover, Plate 1S3-25127-01-00 2 $4.94 $9.88

Steering Knuckle AssemblySteering Knuckle Assy, Left 3GD-23501-10-00 1 $234.66 $234.66

Steering Knuckle Assy, Right 3GD-23502-10-00 1 $234.66 $234.66

Total Cost $1,158.58

Rod Ends at Steering Knuckle

Parameters from Trade Study• Camber = 10°• Caster = 5°• Kingpin Angle = 13°• Scrub = 1.23 in.

Parameters from 2D A-Arm Motion Analysis

• Ride Height = 10.7 in.• Minimum Clearance = 4.8 in.• Total Travel of Tires = 11 in.• Total Travel of Rod Ends = 45.3°• Track Width = 53.625 in.

Steering Parameters• Max Turning Angle of Tire = 36.4°– Rack and Pinion has 4 in. total travel

• Minimum Turning Radius = tan(90°- 36.4°)*WB• Wheelbase = 61.79 in.• Minimum Turning Radius = 7.0 ft• Percent Ackermann = 0%

Exploded View of New Steering Arm Connector

Top Piece of Steering Arm Connection

Bottom Piece of Steering Arm Connection

Parameters from Force Analysis• Shock Force at Full Compression = (271.774, -387.566, 83.466) lbf

– Calculated assuming car landed on only two wheels (275 lbf acting on one tire) and shocks are fully compressed.

• Maximum Centripetal Force = (-112.5, 0, 0) lbf

– Assuming 1g for centripetal force experienced on car, with 50% acting on the front, 90% of that acting on one tire, and 50% of that acting on one a-arm.

• Maximum Braking Force on Bottom A-Arm = (0, 0, -520.3) lbf

– Calculated from 1040.625 maximum braking torque according to Brakes

• Maximum Braking Force on Top A-Arm = (0, 0, -416.3) lbf

• Where X is normal to the right side of the toe box, Y is normal to ground, and Z is normal to the front of the car.

Top A-Arm FEAwith heat treated 6061

Max Stress = 11.72 ksiSafety Factor = 2.56

Max Deflection = 0.023 in.

Bottom A-Arm FEAwith heat treated 6061

Max Stress = 9.27 ksiSafety Factor = 3.23

Max Deflection = 0.035 in.

Bottom A-Arm FEAwithout heat treatment

Surpasses the yield strength of 6061-O, but not the tensile strength

Not accurate because the majority of the a-arms will be stronger material and able to

take the applied force.

Plan to build aluminum a-arms to test and steel

a-arms as backup

Steel a-arms add 4.654 lbs to FS weight. Brings total weight to 86 lbs.

> 8 ksi