Project Overview

The BAJA wheel hubs redesign at Olin College of Engineering aimed to create a lighter, more efficient, and structurally optimized component for off-road racing conditions. The project focused on enhancing vehicle performance through material optimization, improved design geometry, and thorough load analysis, all while ensuring safety and reliability.

New BAJA Wheel Hub Design

Project Scope

The wheel hub is a crucial component in the drivetrain of any off-road vehicle. It not only serves as the primary mounting point for the wheels but also plays a vital role in transferring power from the half shafts directly to the wheels. This ensures efficient power delivery and optimal performance under the demanding conditions of off-road racing. By redesigning the wheel hub, we aim to enhance its structural integrity, reduce weight, and improve overall vehicle dynamics, ultimately contributing to a more competitive and reliable off-road racing machine.

Material Selection

6061-T6 Aluminum

  • Lightweight construction
  • High strength-to-weight ratio
  • Excellent corrosion resistance
Material Analysis of 6061-T6 Aluminum
Image Source: https://www.wellste.com/6061-aluminum-alloy/

Manufacturing Process

Machining Techniques

  • CNC Milling for precise shaping
  • Lathe Operations for spline refinement
  • Material optimization procedures
CNC Manufacturing Process

Structural Analysis

FEA Results

  • Jump Impact: FOS 127.63
  • Bump Load: FOS 35.17
  • Tree Collision: FOS 1.11
FEA Analysis Results

Testing & Validation

Planned Tests

  • Olin Time Trials
  • Track Performance Trials
  • Continuous Improvement Cycle
Physical Testing Setup

Design Process

From Concept to Final Design: A systematic approach to engineering excellence.

Research Phase

  • Analysis of existing designs
  • Industry standards review
  • Competitor analysis
Research Documentation

Initial Design

  • Preliminary sketches
  • Design constraints
  • Performance requirements
Initial Design Sketches

CAD Development

  • 3D modeling
  • Digital prototyping
  • Design iterations
CAD Models

Design Evolution

  • Design 1: Initial Optimization
  • Design 2: Enhanced Performance
  • Final Refinements
Design Evolution

My Role

  • Project Manager Apprentice: Liam Carlin
  • Institution: Olin College of Engineering
  • Project Timeline: 2024-2025