GANDHI INSTITUTE OF ENGINEERING &

TECHNOLOGY,GUNUPUR

TEAM ID: 16116

GENERAL SPEC.S SELECTED

Body Type Space frame(AISI 1018 STEEL )

Kerb Weight 270 Kg

Overall Dimensions 98”*65”*60”

Wheel Base 65”

Track Width Front-52”Rear-48”

Ground Clearance 13”

SUSPENSION TYPEFront Type Travel Unparallel Unequal

Double WhisboneRear TypeTravel

Unparallel Unequal Double Whisbone

Shocker TypeSpring Deflection

Hydraulic Spring Damper

BRAKES SELECTEDType Hydraulic Disc

Brake(Pulsar)

Rotor Size (Front/Rear)

220 mm / 200 mm

Cylinder Dual Master Cylinder

Stooping Distance(m)

12

ENGINE & TRANSMISSION VALUES

Type Manual

Gear box Mahindra Alfa 4

Acceleration m/s2 0.773

Maximum Speed (Kph)

53 kmps

0-53 kmph 21 s

TECHNICAL SPECIFICATION AND PERFORMANCE OF PROPOSED VEHICLE

STEERING VALUESDesign Rack & Pinion

Centralized(11”)

Geometry Over True Ackerman

Turning Radius(m) 2.57

Steering Ratio 12:1

Roll cage Ergonomics Member Roll Cage Member

s

Dimension

Primary Member

RRHRHOFBMLC

FLCLFS

1”OD :

0.120”(3mm)

thickness

Secondary Member

LBDSIMFABUSM

ALL CROSS MEMBERS

1”OD :

0.039”(1mm)

thicknessRoll Cage Material Physical Property

AISI 1018 Mild Steel

Density 7.7 gm/cc

Yield strength 383 MPa

Ultimate Tensile Strength

440 MPa

cost Rs-140/- /ft

Poisson’s Ratio 0.29

Young’s Modulus 205 GPa

Carbon Content 0.18%

Driver’s helmet should have 6” (152mm)clearance to the side of surface(RHO).Roll Cage must provide a clearance of 3” to driver. Spacious enough to accommodate a person with 95th

percentile male to the 5th percentile female population. Reduction in weight due to selection of material with

high strength to weight ratio Smaller thickness is selected for secondary members

resulting reduction in weight. Front end of then RHO members of must be at least 12”

forward vertically from the side bottom. Angle between the FBM and the vertical members is <45

degree. SIM is at 8-14” above the seat bottom.

Material Tubing SAE 1018 Mild Steel

Outside Diameter 25.4 mm

Inside Diameter 19.4mm

Wall Thickness 3mm

Roll Cage AnalysisParticulars Front

ImpactRear Impact

Side Impact

Roll over

Torsoinal Rigidity

Front wheel bump test

Total applied force (N)

8G 8G 4G 2G 2G 1G

Maximum total deformation (mm)

1 12 5.25 1.4 1.4 0.7

Max. Combined stress (MPa)

214 290 325 178 106 250

FOS 3.09 1.5 1.33 2.4 4.14 2.8

Stiffness of Roll cage (N/mm)

4421 2040 736 896 3139 784.2

Roll over Deformation

Rear Impact Deformation

Side Impact Deformation

Front Impact Deformation

Torsional Rigidity Deformation

Bumping DeformationParticulars Constraints Forces applied

Torsional One side of front suspension

Another side of front suspension

Drop Suspension mounting points

At LFS node points

Bump Suspension mounting point

Shocker mounting point

SUSPENSION DESIGN –FRONT / REAR

Static Data's

Camber angle -2.3 deg

Caster angle +3.2 deg

King pin angle 6 deg

Roll centre height 5” from ground

Scrub radius (mm) 45.27

Particulars Front Rear

Spring stiffness (N/mm) 23 18

Spring travel (inch) 5 4

Natural frequency (Hz) 0.78 0.9

Motion ratio 0.79 0.91

Results Roll centre height • Front 241 mm• Rear 341mm Centre of gravity

height = 18 inch Ground Clearance =13 13”

Design Considerations Kingpin and caster angle are kept in such a way that they can compensate each others camber gain, by

providing there individual function. A positive king pin angle is kept to help in steering the vehicle. Roll centre below CG to avoid jacking force. Front ride frequency is greater than rear. Roll axis inclined towards front to give understeer characteristic. Front double wishbone unequal parallel arm to have better traction during cornering.

*Static camber : -2.3•Caster:- +3.2˚*Spring Constant ( Front):- 23 N/mm*Spring constant(Rear) :- 18 N/mm* 1° of toe change per 6’’ of travel* Static Roll Center Height – 5 ‘’ from ground* Wheel Travel 7’’ – Up , 5’’ - Down

Camber change during bump Caster change during bump

Change in Roll Center Height

Graphs of Bump and Roll analysis

Front lower A arm Deformation

% change in ant-dive with bump

Damper Travel During Bump

Toe change during bump

Upright analysis result

Front lower A arm Deformation

Anti Dive Geometry in LOTUS Suspension Analysis

suspension

Spring material Oil Temperd low carbon steel

Spring wire Dia 10 mm

Sprung mass 250 Kg

Unsprung Mass 100 Kg

THERMAL ANALYSIS OF DISC

BRAKES

Brake Geometry Specification

Brake Type 4 Wheel Disc Brake

Split Type Front & Rear

Disc Size Front (mm) Bajaj 220

Disc Size Rear (mm) Bajaj 200

Master Cylinder area(mm2) 285.02

Breaking Torque( Front/Rear) 1047 Nm952 Nm

Design Parameter Values

Static load at front axle (kg) 128.24

Static load at rear axle (kg) 222.75

Total weight of the vehicle (Target) (kg)

350

Dynamic load @ front axle (Braking) (N)

1786

Dynamic load @ rear ( Braking ) (N)

Height of C.G form ground (inch) 18

Distance of C.G from rear axle (inch) 40.55

Distance of C.G from front axle (inch)

23.44

Rolling radius (inch) 12

Coefficient of friction between road and wheels

0.7

In order to achieve “Optimum Brake Balance”, or to achieve 100% base brake efficiency, the ratio of the front and rear dynamic braking forces will be equal to the ratio of the front and rear vertical forces (axle weights).

Under-steering & Over-steering, both possible with brake bias adjustment.

Bias bar takes force from one side and gives to another.

60% of braking capacity should be on front tires due to dynamic weight transfer.

Keeping the 60-40 %, the stopping distance of the ATV will reduce.

While braking the Anti-Dive Geometry reduces the effect of weight transfer.

Calculations done to achieve “Optimum Brake Balance”

128.24 Kg 222.57Kg

C.G

11.89m Stopping Distance

F R

40.56”

18”

85 kg Load trtransfer

STEERING Centralized Rack and Pinion. Over True Ackerman Geometry.

• Design Considerations:

Cot(Ø)-Cot(Ɵ)=(Distance b/w kingpins)/Wheelbase,

Sin(ɑ+Ɵ)+Sin(ɑ-Ø)=2Sin(ɑ), Rof = (b/sin(Ø))+(a-c)/2,

• Specification of rack and pinion: Rack Length(eye to eye) = 11 inches, Rack Travel(centre to lock) = 2.25

inches, Pinion Rotation(centre to lock)=2700

Over True Ackerman Geometry in CATIA

Proposed design in CATIA

Variables values

Type Centrally aligned rack & pinion

Steering rake (inch) 11

Steering Ratio 12:1

No. of turns(cent to lock) 1.3

Turning radius(m) 2.57

Turning angle(Inner) deg. 40

Turning angle(Outer) deg.

27.56

Ackerman angle deg 28.3

steering wheel diameter(mm)

185

Tie rod ( inch) 16.5

11” Rack And Pinion

POWER TRAINENGINE SPECIFICATIONSMAX POWER 10 HP

MAX TORQUE 19 N-m

PERFORMANCEACCELERATION TEST

Acceleration : 0.773 m/s2

0 – 60 kmph in 21.58 s.

HILL CLIMBING TEST

Speed : 13.162 kmph

At a Gradability of 100%.

GEAR RATIO

GEAR GEAR RATIO SPEED

1ST 31.48:1 12 kmph

2nd 18.70:1 21.04 kmph

3rd 11.40:1 34.53 kmph

4th 7.35:1 53 kmph

BASIC CALCULATION

PARAMETER TYPE / VALUE

GEAR BOX MAHINDRA ALPHA

TRANSMISSION ORIENTATION

FORWARD/ REAR ENGINE REAR WHEEL

COUPLING TYPE MANUAL/ DIRECT COUPLING

TRACTIVE FORCE 427.21N

MAXIMUM SPEED 53 kmph

TIME 0-53 KMPH IN 19.07 seconds.

TYRE SPECIFICATION

VALUES

Wheel Size(Front & Rear)

24”*8”*12”

Rim Outer Diameter

12”

Width 8”

Analysis of stress induced in muff coupler

Roll Cage6%

Engine &

Transmis-sion27%

Suspension & Wheel40%

Brakes5%

Steer-ing6%

Safety(Hel-

met,Driver

Suit,Fire Ex-tin-

guisher)

12%

Others4%

Roll Cage20%

Trans-mission

21%

Suspension12%

Wheel & Rim16%

Brakes7%

Steering3%

Safety8% Others

13%

Chart Title

COST AND WEIGHT ANALYSIS PIE CHART

COST- 272650/-

WEIGHT-270 Kg

Sl no. Task name Duration Start Finish

INITIATION STAGE

1. Team selection & allotment of departments 15 days MARCH 5, 2015 MARCH 20, 2015

2. Conceptualization & market availability 10 days MARCH 21, 2015 MARCH 30,2015

3. Sponsorship procurement plan 20 days APRIL 1, 2015 APRIL 15, 2015

4. Team registration 2 days APRIL 16, 2015 APRIL 17, 2015

DESIGN AND ANALYSIS STAGE

5. Design selection & calculations 20 days APRIL 24,2015 MAY 14, 2015

6. Part design & Analysis using various softwares 20 days MAY 20, 2015 JUNE 10, 2015

7. Assembling & rendering 3D view 5 days JUNE 11, 2015 JUNE 15, 2015

8. Preparation of presentation 10 days JUNE 21, 2015 JULY 1, 2015

BAJA SAEINDIA 2016 VIRTUALS, CHITKARA UNIVERSITY, CHANDIGARH 2 days JULY 10, 2015 JULY 11,2015

MATERIAL PROCUREMENT STAGE

9. Stage 1:1018 steel tubes, welding equipments, suspension, power trains, brakes, steering components 20 days JULY 20, 2015 AUGUST 8, 2015

10. Stage 2:Safety and electrical equipments, other miscellaneous items. 15 days AUGUST 13, 2015 AUGUST 27, 2015

MANUFACTURING STAGE

11. FABRICATION STAGE: Roll cage built up, Hub, upright, suspension arms, gearbox etc 32 days SEPTEMBER 1, 2015 OCTOBER 2, 2015

12. ASSEMBLY STAGE: Engine, power train installation, Suspension, Brake, steering system 20 days OCTOBER 3, 2015 OCTOBER 22, 2015

13. COMPLEMENTATION STAGE: Safety, electrical system installation, Aesthetics (body panelling, padding, painting) 15 days OCTOBER 24, 2015 NOVEMBER 8, 2015

DESIGN VALIDATION & REFINEMENT

14. STATIC TESTING PHASEWeld test & Drop test, Go-on-go Test, fuel leak test, eggression testStraight line stability, lock to lock angle, percentage ackermann & turning radiusTop speed test, acceleration test & brake test, Figure of 8 test

8 days NOVEMBER 9, 2015 NOVEMBER 16, 2015

15. DYNAMIC TESTING PHASE•Gradability test Suspension test Manuverability test

10 days NOVEMBER 18, 2015 NOVEMBER 27, 2015

16. ENDURANCE TEST 31 days NOVEMBER 29, 2015 DECEMBER 29, 2015

DOCUMENTATION (SCCS, COST & DESIGN)

16. TECHNICAL INSPECTION•Vehicle launching & promotional activities

8 days JANUARY 1, 2015 JANUARY 8, 2015

BAJA SAE MAIN EVENT-2016, INDORE : 4 days

PROJECT PLAN & VALIDATION REPORT

COLLEGE FACILITIES

MANUFACTURING LAB1.Surface Grinder

2.Pedestal Grinder

3.Bench Drill4.Shaping Machine

5.Planning Machine6.Lathe Machine7.Slotting Machine

8.Power Saw9.Welding

Shop(TIG & MIG)

10.Carpentry Shop

11.Blacksmith shop

AUTOMOBILELAB

1.Air Compressor

2.Impact WrenchTools

3.Screw Jacks4.Machine

Dynamics Lab

MATERIAL TESTING LAB

1.Universal Testing

Machine2.Impact Testing

Machine3.Brinell

Hardness Tester4.Rockwell

Hardness Tester

SOFTWARE AND

SIMULATION LAB

1.CATIA2.Pro-E

3.Solid Works4.ANSYS

TEAM FORMATION AND WORK ALLOCATIONS. No. DEPARTMENT DEPARTMENT HEAD MEMBERS

1 CAD & CAE SUNIL KUMAR PANDA • SHUBHAM CHOUDARY• PANTALA MURARJI

2 SUSPENSION SHUBHAM KUMAR • RAHUL RANJAN• KUNAL ABHISHEK•RISHAB OJHA

3 BRAKING AMIT DASH • ABHIJEET KUMAR• AMIT KR SINGH•ACHINTA MANDAL

4 STEERING KRUSHNA CH BEHERA • NAVEEN KUMAR• PRABHAT KR NANDA•VIVEK GIRI

5 TRANSMISSION TARUN KUMAR MAHTO • SIDHANT TIRKEY• SIDDHARTH MOHANTY

6 FABRICATION RAJNEESH ROSHAN • ALL TEAM MEMBERS

7 PROCUREMENT & MARKETING

P DHANANJAY RAJU • NISHANT KUJUR• JAYPRAKASH GOSWAMI

8 DOCUMENTATION SANAT KUMAR PATRA

9 ELECTRONICS RAVI KUMAR GUPTA • HIMANSHU SOURAV

FACULTY CO-ORDINATOR

• Prof. SHAKTI PRASANNA KHADANGA

•Mr BALA MURALI GUNJI

THANK YOU

TEAM CAPTAIN: SUNIL KUMAR PANDA