96745 team gearedup2012
DESCRIPTION
This presentation describes the design methodology used during one of my projects SAE BAJA 2012.One can visualize the complete model of the vehicle.TRANSCRIPT
TEAM GEAREDUP - 96745 19th AUGUST 2011
DKTE’S Textile and Engineering Institute,IchalkaranjiKolhapur.
SAE BAJA - 2012
Team CaptainSaddam Hussain(B.E. Mechanical)
Faculty AdvisorProf. Mr. A. R.
Balwan
RULE BOOK IMPORTANT PARAMETERSPARAMETER ALLOWED SELECTED
TRACK WIDTH 64 INCH 46 INCH
WHEEL BASE 108 INCH 67 INCH
MAXIMUM SPEED 60 Km/Hr 45 Km/Hr
MATERIAL STRENGTH 365 Mpa 480 Mpa
DRIVER HEAD CLEARANCE
6 Inch 6 Inch
VEHICLE MUST BE SAFE AND EASY TO RIDE. EASY ACCESSIBLE COCKPIT. AESTHETICALLY GOOD . VERY LESS UTILISATION OF READYMADE COMPONENTS. NO ALTERATION WITH THE ENGINE. DRIVER SHOULD BE EQUIPPED WITH SAFETY GEARS AND
MEASURES. PROPER FUEL STORAGE WITH DRAINAGE SYSTEM. INDEPENDENT BRAKE CYLINDERS FOR FRONT & REAR
WHEELS. PROPER & SAFE CLEARANCES.
CHASIS…DIMENSIONS: Length= 87 inch Height= 48 inch Width= 33.02 inch At front end= 13.4 inch At rear end= 15 inch
MATERIALS: Steel IS 1239
WEIGHT:
WEIGHT APPROX. :- 68 KG
PURPOSE : Material -- High yield strength and cost which is moderate. Roll Cage – Simple design will lead easy manufacturing with future modifications and effective utilisation of space.
ADVANTAGE : More space for the driver to easily enter and exit the vehicle. Suitable for long and bumpy terrains.
Side impact members –BENDED- More space & clearance between the member and knees for SAFETY.
OUTER DIAMETER: 33 mmTHICKNESS : 3 mm
ERGONOMIC AND AESTHETIC VALUES
SPACIOUS COCKPIT COMFORTABLE HEIGHT & INCLINATION OF STEERING
WHEEL SMALL WHEELBASE FOR EASY MANEUVERABILITY. SIM (SIDE IMPACT MEMBER) MODIFIED FOR INCREASING
COMFORT OF THE DRIVER. SIM
WHOLE WEIGHT OF CHASIS SUPPORTED OVER 2 PARALLEL L-CHANNELS. INCLINATION OF 6 DEG. AT FRONT END OF LFS – NATURAL WHEEL
TRAVEL DURING FRONT HUMP ENCOUNTER. EVERY PART HAS BEEN DESIGNED UNDER APPROPRIATE PROPORTION. WELD JOINTS REPLACED WITH BENDS TO ENHANCE STREAMLINE
EFFECT.
L-CHANNEL
FRONT
TOP
SIDE
6 Deg
FEA RESULTS & CONCLUSIONLOAD INFORMATION
FRONT IMPACT AT FULL SPEED OF 60 Km/hr.
MESH INFORMATION
FEAFRONT IMPACT SIDE IMPACT
OTHER PARTS…
REAR ARM FRONT A-ARM
FRONT HINGE REAR HINGE
FRONT VIEW SIDE VIEW
ISOMETRIC VIEW TOP VIEW
48 inch
66.8 inch
46 inch
12 inch
TRANSMISSION
GEARBOX : MAHINDRA & MAHINDRA ALPHA CHAMP Having 4 forward + 1 reverse gear with built in differential and universal joint .Configuration of our vehicle would be REAR ENGINE REAR WHEEL DRIVE CALCULATIONS :
ENGINE SPECIFICATIONS: Lombardini LGA 340
Rated Power: 8 kW at 4400 rpm Max Torque: 19 Nm at 3000 rpm
TYRES : WHEELS :DIAMETER 24 INCHES , WIDTH – 12 INCH R15-SKODAATV TIRES
1ST - 6.8 TO 10.06 Km/hr2ND -11.55 TO 16.94 Km/hr3RD - 18.94 TO 27.78 Km/hr4TH - 29.38 TO 43.10 Km/hrREVERSE – 3.92 TO 5.75 Km/hr
BRAKESREAR : Internal Expanding Shoe BrakesFRONT : Disc Brakes
Weight falling on each rear wheel 48 kg
CHARACTERISTICS
Independent Hydraulic reservoirs
Four wheels must lock at the same time.
Produce required force to stop the vehicle at the maximum speed.
SR NO.
V
(km/hr)
R F(braking)
(N)
f(deceleration)
(m/s2)
1. 50 1 808.525 2.99
2. 50 .55 1281.86 4.74
3. 50 .45 1473.56 5.45
4. 50 .40 1593.66 5.89
5. 50 .35 1899.73 7.03
SR. NO. V(Km/hr) f (m/s2) R – R’(N) S(m)
1. 50 2.99 290.63 32.26
2. 50 4.74 460.73 20.35
3. 50 5.45 529.74 17.7
4. 45 4.74 460.73 16.48
5. 45 5.45 529.74 14.33
6. 45 7.03 683.32 11.11
7. 35 5.45 529.74 8.67
8. 35 5.89 572.51 8.02
9. 35 7.03 683.32 6.72
SUSPENSIONSUSPENSION DEMANDS: Ground clearance to be 11-12 inches
PARAMETER
spring rate 19.71 N/mm
Total number of coils
15.00
Number of active coils
13.00
Wire diameter 11.00 mm
Free length 390 mm
solid length 150 mm
solid load 4827.22 N
FIGURE FROM SUSPROG SOFTWARE
TYPE- 14” Rack and Pinion systemRACK C- FACTOR - 52.00STEERING RATIO- 12.10
TURNING RADIUS- 3.6m( tire contact centre) LH/RH
STEERINGFor steering calculations we used Susprog software
SR . NO. A(degree) L1(inch) r 1(m) L2(inch) r 2(m)
1. 30 70 22.07 60 18.9
2. 45 70 14.72 60 12.62
3. 60 70 11.04 60 9.47
4. 90 70 7.37 60 6.32
5. 120 70 5.54 60 4.75
6. 135 70 4.93 60 4.22
7. 150 70 4.44 60 3.81
8. 210 70 3.19 60 2.74
9. 240 70 2.80 60 2.40
10. 300 70 2.26 60 1.94
11. 360 70 1.91 60 1.63
ELECTRICAL SYSTEMS IGNITION SWITCH 12v 44Ah BATTERY HORNS
TAIL LIGHT HEAD LIGHT
ENGINE MOUNTING Lombardini LGA 340
C-CHANNELS WITH HOLES ENGINE MOUNTING
BOLTING FINALISING
DFMEA
INNOVATIONHYDRAULICALLY & COIL SPRING OPERATED VARIABLE
SUSPENSION SYSTEM OIL TANK
OIL PUMP OIL PUMP
OIL TANK
OIL CYLINDER
OIL CYLINDER
NORMAL MODE OPERATIVE MODE
IT PROVIDES OVERALL VARIABLE STIFFNESS TO THE SUSPENSION SYSTEM.
HELP TO INCREASE/DECREASE GROUND CLEARANCE. EASES THE DRIVER WHILE DRIVING AROUND A RADIUS.
DESIGN VALIDATION PLAN
RELIABLE AND SAFE
SR.NO.
COMPONENT
PROPERTY TEST VALIDATION
1. Chassis welding Destructive testing
Comparing the stress level obtained with permissible
level for the given material.
Dimensions Measuring Manually
Rechecking and comparing with 3-D model
2. Brakes Pedal Position
Trials to be carried
out
Suitable for both of our drivers.
Brake force Trial on vehicle
Safe and short stopping distance.
3. Steering Wheel position
Trial on vehicle
Comfort to the driver
Maneuverability
Static test Degrees of turn of tires per degree of rotation
of wheel.
4. Transmission Engine mounting
Test for Vibration
Centre position & less vibration.
Axle length Trial Compare with standard assembly.
PROJECT PLANSR NO. TASK DEADLINE
1 STUDY OF RULEBOOK 2ND Week of January
2 DATA COLLECTION 15 th Feb
INITIAL DESIGN 28th April
3 3-D MODELING 15th May
4 PDR 26th May
5 ANALYSIS 30th July
6 COST ESTIMATION 20th August
7 FINAL DESIGN 30th August
8 MARKET SURVEY 30th August
9 SPONSORSHIP 25th September
10 MATERIAL PROCUREMENT 20th October
11 FABRICATION AND ASSEMBLY 10th December
12 TESTING 10th January
13 FINAL DESIGN REPORT 20th January
RELIABLE AND SAFE
1. Ghorpade Abhijeet2 Vivek Mahajan3.Thombare Sagar4. Ashish Rajoba5. Siddhesh Yadav
1. Swapnil Babar2. Ajay Borate3. Akshay Rukhade4. Rahul patil5. Nityanand Khushwaha6. Hariom
1. Shahnawaz Tambe2. Mahesh Kale3. Katti Indrajeet4. Aniket Patil5. Thorwat Aniruddha
1. Saddam Hussain2. Indranil Banerjee3. Abhineet Badve4. Ashish Patil
TEAM STRUCTURE AND DISTRIBUTION
1. Saddam Hussain (captain)2. Pranav Kawre3. Pankaj Salgare4. Kulkarni nilesh5. Chetan Bhupal
COLLEGE FACILITIES-HIGHLY EQUIPPED WORKSHOP - CNC Machines -Drilling Machines
- Milling Machines - Lathes
- Sheet Metal Bending Machine - Arc Welding
- Smithy shop - UTM
- CAD Lab-ADVANCED HOYT TRAINING LAB- LIBRARY- Books and Journals on Automobile.- INTERNET + 24 hr Wi-fi - SEPARATE SPACE FOR SAE BAJA VEHICLE FABRICATION.
SAFETY•PRECAUTIONS TAKEN :
• A five point restraint harness • Single metal‐to‐metal quick release lever type
buckle• Engine Shield.• Seat Belts as per the rule of SAE• Avoid breaks in the Design of Roll- cage.• Helmets and fire-proof suite.• Fuel spill-drip pan.• Fire-resistant roll- cage padding.• Separate master cylinders for braking system.• Avoid or remove sharp edges or burrs.