BEANT COLLEGE OF ENGINEERING & TECHNOLOGY, GURDASPUR (GOVT.)

(An Academic Autonomous and NBA Accredited Institute )

TEAM ID : 16190

SPECIFICATION VALUES

Overall Length 2447.20mm

Overall width 1828.80mm

Front track width 1470 mm

Rear track width 1550 mm

Wheel base 1850 mm

Ground clearance 297 mm

Wheels- Front & rear

22”12”7” & 22”12”10”

Maximum speed 55.6 km/hr

Maximum acceleration

7.4 m/s²

Gradabilty % 86.5 %

Stopping distance 19.4 m (40 km/hr)

Kerb weight 190 kg

Ratio FAW & RAW 45:55

OVERALL VEHICLE DETAILS

ROLL CAGE

Materials AISI 1018 AISI 4130 AISI 1020

Availability 4 3 2

Strength 3 4 4Cost 4 2 3Weight 3 4 4Total 14 13 13

Material used AISI 1018Yield strength 365 MPa

Tensile strength 440 MPaElongation 15%Outer diameter 25.4 mmWall thickness 3 mmOver all length 2083.6 mmMax. width 718 mmWeight 54 Kg

Material selection

Ergonomics Related to Cockpit :• Cockpit is designed in such a way that driver can exit within 5 seconds in an emergency .• RRH is given an angle of 15 deg. To give a good sitting posture to the driver. • Front bracing members are adjusted in a such way to give a wider view of vision. • Side impact members are designed to protect the driver from external threats.

Carbon 0.18 %

Iron 98.8 %

Manganese 0.6 %

Sulphur 0.05 %

Chemical Composition :

Welding used for the manufacturing of the roll cage is MIG welding . Due to its lesser cost and good strength .

ANALYSIS OF ROLL CAGE

Front impact force - 24000 N (8.6G ) Max. stress - 184 MPa Deformation - 3.227 mm Factor of safety – 1.98

Rear impact force - 24000 N (8.6G) Max stress - 293 MPa Deformation – 3.06 mm Factor of safety - 1.24

Roll over force - 2774 N (1G )Max stress – 157 MPa Deformation – 6.4 mmFactor of safety - 2.32

Side impact force - 11928.2 N (4.3G) Max stress - 302 MPaDeformation – 3.9 mm Factor of safety - 1.21

Parameter

Case I

Case II

Case III

Size of Mesh (Units)

20 10 8

No. Of nodes 219584 434629 485534

No. of Elements

133446 236481 253079

Max value of Von-Misses Stress (MPa)

225.62 285.89 290

Percentage Error

52.27 29.31 1.8

So we have selected the mesh size = 8 Because its Percentage error is less than 5 % after performing iteration .

SUSPENSION DESIGNType of Suspension (Front And Rear) - INWARD CONVERGING TRANSVERSE DOUBLE WISHBONE

CHARACTERSTICS FRONT REAR

GROUND CLEARANCE (m)

.297 .315

ROLL CENTER HEIGHT (m)

.231 .281

CAMBER (deg) -1.21 -1.50

CASTER (deg) 3.18 3.18

KPI (deg) 12.53 3.18

MOTION RATIO .8 .9

WHEEL RATE (N/mm) 9.645 15.612

SPRING STIFFNESS (N/mm)

15.07 19.274

NATURAL FREQUENCY (Hz)

2.41 2.46

RIDE FREQUENCY (Hz) 1.96 2.27

ROLL STIFFNESS(Nm/deg)

202.54 327.15

CG Height (m) – 0.505 Scrub Radius (m)- 0.067 Sprung mass (kg) – 204 Unsprung mass (kg)- 76

Material Used – 4130MAX . VON MISES STRESS-175MpaFOS-2.62

Material Used- 4130MAX. VON MISES STRESS- 148MpaFOS- 3.1

Bump travel (front)- 7inchBump travel (rear)- 6inchDroop travel (front)- 5inchDroop travel (rear)- 4inch

BRAKES

Disc Brakes X-split brake circuit with master cylinder of Maruti 800 Bosch tandem cylinder (OEM) having bore diameter ¾

Inch and piston area of 0.4393 sq. Inch. Discs of Maruti Zen is used for front wheels and TVS Apache RTR 180 is used for rear wheels and calliper of respective discs are used. For Brake fluid DOT 3 is taken.

SPECIFICATIONS VALUE

FRONT DISC DIAMETER 182mm

REAR DISC DIAMETER 270mm

FRONT CALLIPER PISTON 50mm

REAR CALLIPER PISTON 32mm

BRAKE FORCE 2058N

PEDAL FORCE 70lbs

DECELERATION 7.35m/s²

PEDAL RATIO 6:1

FRONT BRAKING TORQUE 189.04Nm

REAR BRAKING TORQUE 280.36Nm

CALLIPER PAD FRICTION COEFFICIENT(FRONT WHEEL)

0.08

CALLIPER PAD FRICTION COEFFICIENT(REAR WHEEL)

0.29

SPECIFICATIONS VALUE

FRONT CLAMPING FORCE 12.86KN

REAR CLAMPING FORCE 3.548KN

CYLINDER PRESSURE 6.59MPa

MEAN BRAKING RADIUS 91.85mm

WEIGHT TRANSFER 552.814N

STOPPING DISTANCE 19.4m(40km/hr)

STOPPING TIME 1.75s(40km/hr)

STEERING

STEERING SYSTEMOver steerAckerman % - 80

Steering angle - inside - 40.51 (deg.) outside - 26.98 (deg.)Turning circle radius – 2901.2mm

STEERING GEAR – R & P RHD (MARUTI SUZUKI 800)Rack travel – 120mmTurns lock to lock, rev. – 3.25

Steering ratio – 12:1OBJ center distance - 110mLength of Tie rod – 397mmLength of steer arm – 86.9 mmSTEERING COLUMN CollapsibleWithout power assist

LOTUS STEERING ANALYSISSteer Toe Ackerman Turning circle Travel angle (%) radius (mm) {SAE} (mm) (deg.) 45.00 38.00 81.70 2979.55 30.00 22.70 71.53 4955.39 15.00 10.57 67.35 10418.21 0.00 0 66.16 0-15.00 -9.62 67.35 10418.21-30.00 -18.63 71.53 4955.39-45.00 -27.25 81.70 2979.55

STEERING WHEELSteering wheel diameter -390mmSteering wheel torque – 58.5Nm

Wheel Geometry

POWER TRAIN

• ENGINE SPECIFICATIONS• Briggs and Stratton• 305CC • 10HP• 19Nm at 2800 rpm

Overall gear ratios

Tractive force (N-m)

Maximum velocity km/hr

Maximum acceleration m/(sec) ²

Gradability %age

37.5:1 2294 9.4 7.4 86.5

25:1 1529 13.5 4.7 57.6

12.5:1 764.6 28.2 2.0 28.8

6.25:1 382 55.6 0.6 14.4

• TCVT= 14.5 lb-ft * (12 in/ 1 ft) * (3/1) * 0.83 = 433 in-lb =48.9Nm• Factor of safety for shaft is 5.05

• For tire diameter =22inch the maximum velocity attained by vehicle is 55.6 km/hr• N= Transmission efficiency = 0.85• Torque on the wheel=420ft-lb = 569.4Nm• 12.5:1 Gearbox is used

• TRANSMISSION : CVT COUPLED WITH MAHINDRA ALPHA GEAR BOX

• LAYOUT OF ENGINE , CVT AND GEAR BOX

COST ANALYSIS & WEIGHT DISTRIBUTION

26.50%

20.50%19.2

6%

6.30%

12.60%

15.14%

COST ANALYSIS

POWER TRAIN

SUSPENSION & STEERING

ROLL CAGE

BRAKING

WHEEL TIRE

SAE REG-ISTRATION

24.28%

19.28%19.40%

13.92%

23.00%

WEIGHT DISTRIBUTION

TRANS-MISSION & BRAKING

SUSPENSION & STEERING

ROLL CAGE

WHEEL & TIRE

DRIVER

PROJECT PLANNING

Part Function Failure Models Precaution Validation Accomplishment

Roll Cage Basic Soul Of Vehicle And To Protect The Driver

When Material Reaches To Ultimate Stress Value.

Use Of AISI 1018 Steel Having Yield Strength Value Equal 370 Mpa.

Welding Test Universal Testing Machine

ENGINE To Generate Power

Spark Plug Failure/Improper Functioning Of Old Filters.

Regular Check Of Spark Plug & Filter Change.

Fuel Leak Test

Vehicle Should Be Tested In Various Road Condition

TRANSMIS-SION

To Transmit Power From Engine To Wheels

Improper Lubrication/Unexpected Load.

Use Of ISO Grade Oils .

Speed And Acceleration Test

Road Test

SUSPENSION To Absorbs Shocks And To Give A Smooth Drive

When Coil Reaches To Solid Length.

Proper Calculation And Assumption In Designing.

Wheel Travel Inch Tape

BRAKES To Reduce The Speed When Required And Emergency Stop

Circuit Failure Due To Leakage Worn Out Break Pads.

Bleeding Of Vehicle’s Break Before Every Run, Checking And Replacement.

Breaking Test Road Test

WHEELS To Provide Good Traction

Inappropriate Air Pressure/Puncture Tire.

Checking Of Air Pressure At Every Refuel Backup Extra.

Tire Air Pressure

Air Pressure Gauge

DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN

TEAM COMPOSITION & COLLEGE FACILITIES TEAM STRATEGY FACULTY ADVISOR : SANDEEP GANDOTRA DEPARTMENTS TEAM MEMBERS

1. ROLL CAGE ARSHDEEP SINGH, AMAN RANA,VINAY KUMAR (Captain) ,LOVY MINHAS, SAEED AKHTAR, SACHIN, SATNAM SINGH

2. TRANSMISSION ANUJ BHARDWAJ, SHIVAM BHARDWAJ,AMARJEET GULERIA, NAVJEET SINGH, KASHISH MAHAJAN, RAKESH ,SHAMSHER SINGH,VARUN SHARMA

3. SUSPENSION ANSHUL SHARMA, ABHISHEK THAKUR, VINAY KUMAR, ANUBHAV MAHESHWARI, ABHINAV KUMAR, NITISH PANDEY, SATISH

4. BRAKING GAGANDEEP SINGH, ANUJ BHARDWAJ

5. STEERING AMAN RANA, ARSHDEEP SINGH, AMARJEET GULERIA

6. DRAFTING & ANALYSIS

KRISHNA KHOSLA,JATIN SARINE

7. MANAGEMENT ANUBHAV MAHESHWARI,SHAMSHER SINGH,UTKARSH

COLLEGE FACILITIES

For Roll Cage , Each and every equipment available in welding shop.

For Custom Knuckle , requirements are available in Carpentry , Foundry and machine shop.

For Seat Installation and Sheet Covering of vehicle , equipments are available in welding and sheet metal shop.

For clamping of Wishbones , each and every requirements are available in Central Workshop.

For Assembly and Installation of all other parts of vehicle, requirements are available in Central Workshop.