2017
Full-Driveline Subframe
Cornell Baja
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One of my first projects on the Baja team was an investigative research project for the Frame subteam. The motivation for this was to assess the viability of a full-driveline subframe, that way the engine, gearbox, and CVT could all be removed from the rear at once.
I created a design that packaged within a previous vehicle, OD12. This was challenging because the vehicle was not designed around these components, so the subframe beams needed to weave around existing geometry and preserve the mounting points for the systems like the gearbox. I also determined that a few parts would still need to be disassembled in order to remove the driveline, such as the CVT guard.
Analysis was then conducted to understand the structural integrity of the assembly. The loads required were the reaction forces from the gearbox, cyclic engine loads, and preload forces from bolts. This was of high importance as we had previously seen the frame cracking near the engine and fatigue failures around subframe components. In fact, during this same season, other members of the Frame team ran multiple strain gauge and lifetime tests to understand the loads the design was seeing and expected life for similar subframe parts. It was very educational to be involved in this project around the same time this work was ongoing.
After the design was qualified in ANSYS, I spent time working on mass reduction and considering additional frame supports around the midpoint of the beams. Ultimately however, I came to the conclusion that the design may not be viable or advantageous. Compared to the frame structure that already existed, the full-driveline subframe was heavier and may be too difficult to remove from the vehicle as one piece. Nonetheless, this was an educational project for me, and I was happy to get experience with cyclic loads and challenging packaging problems.