design presentation roadies - nri institute of...
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L/O/G/O
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ROADIES
National Institute of Foundry & Forge
Technology , Ranchi
Design Presentation
Regd. ID : 81341
TEAM CAPTAIN
TEAM VICE-CAPTAIN
TECHNICAL
Design &
Analysis
Roll Cage Steering Suspensions Tires &
Brakes
Fabrication
MANAGEMENT
Publicity Sponsorship Procurement
RICHARD DOLEY AKSHAY TRIPATHI
VIKAS UTSAV
KR. SAMBHAV UTSAV MAHTO
ANUROOP, RAJA,SATISH
DHARMENDRA RAJAT
BITTU GUPTA ROHIT UJJIR
MANAS GOND HITESH GODWANI
CHAITANYA DWIVEDI VISHAL PANDEY
ABHIMANYU
RAJ VARDHAN ANKIT GUPTA
ASHUTOSH
RISHIKANT
TEAM ORGANIZATION
ROLL CAGE Material Carbon Steel AISI 1018
UTS 365 Mpa
Carbon content 0.18%
Outside dia.:
Wall thickness:
25.4 mm
3.05 mm
DESIGN METHODOLOGY
WELD JOINTS
• Driver-oriented Cockpit design. • Light weight, Compact and simple.
• High Roll stiffness and structural rigidity
• Easy egress during mishap.
• Least no. of welds and members
Number of weld joints
Weld length
= 62 = 4.787 m
Roll Cage Analysis (Software: ANSYS 13.0)
Front Impact Analysis At Speed : 60 km/hr (16.67 m/s)
Impact Time : 0.1 sec
Thus, Load= 60000 N on front members.
Max STRESS : 174 Mpa
Max DISPLACEMENT : 2.38 mm
Factor of Safety: UTS/Smax = 365/174
= 2.1
Side Impact (Safe case of Side Roll over) Load: 2G loading (6180 N) on side members.
Max STRESS : 69.4 Mpa
Max DISPLACEMENT : 2.26 mm
Factor of Safety : 365/69.4
= 5.25
Roll Over (Dynamic) Analysis Load: 2G Horizontal on side members
1G Vertical on top members.
Max STRESS :136 Mpa
Max DISPLACEMENT : 5.5 mm
Factor of Safety : 2.68
Suspension: Double Wishbone Parallel SLA
Upper arm 312 mm
Lower arm 338 mm
Upper arm 263 mm
Lower arm 287 mm
Front Lower arm , centre
Rear Upper arm, inner
SHOCK MOUNTING
LOCATION:
LENGTH OF A ARMS:
Front
Rear
REAR UPPER ARM
FRONT LOWER ARM
Front 81.66 mm
Rear 114.82 mm
ROLL CENTER HEIGHT:
Steering
Gear Ratio 12:1
Caster 5° Positive
Camber (static) 2° Negative
Toe-in 10 mm
King-pin Inclination 12°
Scrub Radius 44 mm
Lock Angle 40° (approximately)
No. of turns to steer from Extreme Left
to Extreme Right
2.66 turns
Turning Radius
Target Specifications:
• Rack and Pinion; simple design and easy to install.
•100% Ackermann geometry
Braking System
Pedal Ratio 6.2:1
Braking Effort 1300 N per wheel
Deceleration 7.53 m/s2
Stopping distance 21.5m (max speed 60 km/h)
Assumption: Brake Efficiency = 70%
Coefficient of friction =0.65
Formula used ῖ = BfwR/r Bf = Mag s = v2/ 2gaₓ/g
Maruti 800 calipers and disc will be used
Target Specs:
Features:
Hydraulic disc brakes
Two independent braking circuit
Equipped with SMART Turning Assistance System
Two servo motor assisted valves on rear circuit.
While turning left, on application of brakes will lock both the
front wheels and rear left wheel.
Rear right wheel with drive will get moment along these 3 locked
wheel hence turning would be easier.
Power Train
Torque* (ft-lbs,
gross) 14.50
Engine
Displacement (cc) 305
Number of
Cylinders Single
Engine
Configuration Horizontal Shaft
Engine
Technology OHV
Length (in) 12.3
Width (in) 15.4
Height (in) 16.4
Weight (lbs) 50.4
Bore (in) 3.12
Stroke (in) 2.44
Engine Fuel Gasoline
SPARK PLUG RC12YC
Briggs and Stratton Engine:
10 hp OHV Intake
20S332 0036 New engine
with 3800rpm
Overhead Valve Design (OHV)
Runs cooler and cleaner delivering
more power, longer engine life and
improved fuel economy
Flange Coupling
Safety & Ergonomics Kill switches will be installed
to kill the ignition in case of
emergency
All rotating parts will be
properly shielded with sheet
metal. Splash shields and Drip
pans will also be provided
5 point harness seat
belt system along with
neck restraint and arm
restraint
Belly pan running entire
length of cockpit, Roll
cage foam padding and
body panels will be
provided
Fire extinguisher within
the reach of driver will
be provided
SAE grade brake lights
will be installed and all
wiring will be properly
insulated and clipped.
Pivoted bumper with spring
support in front
of vehicle to absorb energy
from collisions
Racing type 3 ways
Adjustable seats, for
driver comfort.
Belly pan and Roll
cage padding
Gear indicator to
enable quick gear
shifts
Design Specifications
Overall length 2.3 m
Track width Front: 1.55 m
Rear: 1.45 m
Wheel base 1.60 m
Overall weight 310 Kgs (inclusive of Driver)
Engine Briggs and Stratton 10hp OHV
Transmission Mahindra Alfa(modified)
Tires
Rims
22 x 8 inches, 6 ply ATV
10 x 6 inches
Roll Cage SAE 1018 seamless steel tubes
1” OD and 3 mm wall thickness
Suspension (front and rear) Double Wishbone suspension
(Parallel and unequal arms)
Steering System Customized Centered Rack and Pinion
Gear Ratio = 12:1
Braking (front and rear) Hydraulic Disc brakes
Maximum Torque 19 Nm @ 2900 rpm
Maximum Speed 60 KMPH
2-D views
Final View
Design Validation Plan
No Description Accomplishment
Targets
Allotted
Resource
Means Of Accomplishment
1. Welding test Strength of welded
components should be within
permissible limits.
Abhimanyu
Yadav
Universal Testing machine
2. Ground Clearance
Test
Should not be less than the
specified value i.e. 10 inch
Ashutosh
Saraswat
10 inch Spacer.
3. Braking Test The vehicle should stop within
safe limits and all the wheels
should be locked
Ankit Gupta To be tested on track with 2 different observers
for wheels on each side. Braking distance to be
measured from point of brake application to
point of stop.
4 Wheel Travel Should be at least 6-7 inches
(jounce rebound)
Raja Sah Ruler
5. Straight Line Stability Should move in a straight line
when steering is at neutral
position.
Rohit Ujjir Driving the car in neutral steering position
parallel to the white strips on road.
6. Turning Radius Should be approximately
equal to the calculated value.
Anuroop
Kulshresta
Radius will be measured using measuring tape.
7. Fuel Leak Test Should not leak fuel or fluid at
any circumstances.
Vishal Pandey Vehicle should be tested in various roads
conditions and any case of spills to be
scrutinsed.
8. Speed and
acceleration test
By recording the time travel
while traversing a path
Hitesh Godwani Obtained data shall confirm the calculated
value
College & External Facilities MACHINING Center Lathe Universal Milling Machine Grinding Machine Drilling Machine WELDING
Metal Inert Gas welding machine TIG welding machine Electric arc welding machine
MANUFACTURING MACHINES
CNC Milling Machine
Hot Isostatic Press(HIP) Machine
Rapid Prototyping Machine
TESTING MACHINES
Brinell Hardness testing machine(3000 kg)
Universal tensile testing machine(60 tonne)
EXTERNAL FACILITIES:
CNC Pipe Bending.
Laser Cutting (for hubs).
Paint Equipment.
Project Plan
Cost Estimates
Category Items Cost
Frame Steel tubes, Sheet Metal,
Welding supplies, roll cage
padding etc
37,200
Power Train Engine, transmission, shifters,
chains, sprocket, couplings etc 47,000
Wheels and tires Rims & tires(4+2) 39,900
Suspension Shocks, springs, A arms, uprights,
hubs, spindles 22,000
Steering Rack & pinion, steering column,
steering arm, steering wheel, tie
rods etc
11,600
Safety equipments Driver’s suit, helmet, fire
extinguisher, harness system,
restraints, kill switch etc
37,500
Braking Calipers, master cylinders, servo
motors, brake lines etc 14,500
Misc Travel, transportation,
accommodation etc 30,000
Total 2,39,700
THANK YOU!!!