The Potent Portal Axle Project MENG 3309 MECHANICAL SYSTEMS DESIGN SECTION 032 – GROUP #3 REPORT SUBMITTED BY: Bobby Grimes Ruaa Selman Charles Canales We certify that the narrative, diagrams, figure, tables, calculations, and analysis in this report are our work. DATE REPORT DUE: February 6th, 2022 DATE REPORT SUBMITTED: February 6th, 2022 MECHANICAL ENGINEERING DEPARMENT COLLEGE OF ENGINEERING THE UNIVERSITY OF TEXAS AT TYLER 1. Select one category of your project from the following list. SAE Baja 2. Tentative title of your project The Potent Portal Axle Project 3. Describe reasons to select this topic of project. While every member of our group has varied engineering interests, we all share a passion for cars, trucks, and specifically off-road vehicles. Due to this shared interest, we feel the SAE Baja competition is a suitable topic. 4. Set up your design goals and describe design constraints (or technical limitations). The goal is to give SAE Baja a competitive edge by designing a portal axle hub. A portal axle increases the ride height of a vehicle, including the suspension components, which provides a distinct advantage when crawling of rocky terrain. The portal axle can also provide a reduction in gearing at the hub, which can allow lighter drivetrain elements. The portal axle must conform to the ruleset for the 2022 SAE Baja competition. To be allowed in SAE Baja, the portal axles must be sized to fit the SAE Baja vehicle under the 2022 regulations. To gain a competitive edge, the portal axles must be as light as possible while still strong enough to deal with the rigors of offroad competition. It also must be simple enough for college students to fabricate and assemble on a tight schedule. It must be within the budget of a collegiate team as well. 5. Explain design methods and approaching strategies in brief. AGMA method will be used to decide which gears are suitable for the task given the vehicle weight, engine power expected. Candidate materials will be down selected for the housing. For each material, the portal axle housing will go through design optimization for each of the candidate materials. Finite Element Analysis will be performed on each of the optimized housings for each material to find which is the lightest and most compact, while still providing adequate strength for the competition and staying within size constraints. Ease of fabrication will also be a consideration. Autodesk Inventor will be used for drafting, stress analysis, and for design optimization. 6. Explain what factors (or concepts) would be innovative and creative in your project, compared to other existing concepts or techniques or methods. This portal axle design will be smaller and lighter weight, made specifically for competition. Portal axles are typically used in the realm of larger off-road vehicles and are made extremely heavy and strong to withstand extreme abuse. SAE Baja vehicles are typically much smaller due to regulations, ease of manufacture, and for competitive edge. Designing a portal axle hub specifically for a SAE Baja sized vehicle will give an appropriately sized portal axle that provides the benefits, such as increased ground clearance, gear reduction, without the detriments that off-the-shelf portal axles have, such as weight, size, and cost. 7. Verification and validation plans for the proof of concept (validation of finite element model by comparing FE results with theoretical calculations or existing references and/or experimental results. 
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