faculty college of engineering department of … · 2018-06-01 · 1 suraj s d founder & ceo,...
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FACULTY COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING
In association with
RECTANGLE AUTOMOTIVE TECHNOLOGIES
PRESENTS
30-DAY INHOUSE RALLY CAR BUILDING INTERNSHIP
10th April to 9th May 17
BRIEF REPORT
RESOURCE PERSON DETAILS
SI NO NAME OF THE GUEST DESIGNATION
1 SURAJ S D FOUNDER & CEO, RECTANGLE AUTOMOTIVE
2 RAMCHANDRA B KULKARNI CONSULTANT, RECTANGLE AUTOMOTIVE
3 VIJAY THARD CONSULTANT, RECTANGLE AUTOMOTIVE
4 JOYTHIVANNAN SENIOR ENGINEER, KGTTI
5 AVINASH IDEAL MOTORSPORTS
6 RAJATH KATTIMANI TORQUE AUTOMOTIVE SOLUTIONS
7 VIDYASAGAR INTERN, RECTANGLE AUTOMOTIVE
8 SUHAS R INTERN, RECTANGLE AUTOMOTIVE
9 ANISH BIWAS INTERN, RECTANGLE AUTOMOTIVE
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Week 1
Interns have undergone theoretical and practical training on IC engines, sensors, actuators, engine cooling,
lubrication, exhaust systems and turbo-charging. Activities are performed to make sure every individual intern have the
assessment sheet for each module. And interns are guided one on one from trainer. Such, every individual point out the
sensors position, function, failure cause & trouble shooting.
Mr.Vijay Thard and Suraj S D have engaged the training for the contents. First 3 days of the training have
brought up the confidence in interns to physically know all the physical components of above mentioned topics.
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Interns have formed into team of 5 and involved in measuring the dimensions of the vehicle such as
wheel base, turning radius, front & rear overhang, departure & arrival angles. Significance of all the physical
parameters have been taught by trainers.
Vehicle dimension activity sheet.
Tyres
Followed by training modules on automotive tyres. Module consist of understanding the tyre terminology,
specifications, types, applications, tyre failure and cause analysis for the failure. Team of 2 interns have given with the
activity sheet and set of tyres after the theory sessions to perform the detail understanding of all parameters.
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Car dis-assembly
Activity involves interns to dis-assemble the exterior components of the car such as bumper, front grill,
fenders, rear bumper & wheel cover.
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Under-body systems
Dis-assembly of Engine guard, exhaust systems and lighting system
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Week 2
Welding training
Expert from Karnataka German Technical Training Institute has engaged the training for welding
module. Module consist of practical and theory sessions on MIG and ARC welding.
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Tube Notching theory
Activity to perform tube notching for 900, 600 & 450 and further to perform welding to join notched
pipes.
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Tube Notching practical’s
Preparing the workpiece for tube notching, each intern practiced the notching activity for different
angles. Tube welding is practiced for the same workpiece.
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Suspension dis-assembly
Dis-assembly of antiroll-bar, torsion bar and suspension dis-assembly practice. And session on
suspension has been delivered by Vidyasagar. Suspensions components, variants and different set-up for
suspension on racing and rallying.
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Training on Brakes and Suspension
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Roll-cage design
Roll-cage serves the primary function to provide the safety for the driver & co-driver. FIA defines the
regulations for roll-cage design, students have taught on how to take dimensions for roll-cage design and
interns have created the 1:1 scale drawings.
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Week 3
Interns have involved in dis-assembling the engine from the car and strengthen the chassis to mount
the roll-cage in tandem team of students have built the 1:1 prototype of the roll-cage.
Chassis strengthening
Engine Dis-assembly preprations
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Engine dis-assembly from car
Dis-assembling engine have been the wonderful experience for interns.
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ECU Tuning
Rajath, Torque motors, explained interns about ECU tunings and re-mapping in order to enhance the
vehicle performance in the rally. During the course students have practiced the tuning and trainer have
provided the ECU maps of Skoda Octavia. Rajath explained about the hardware and software necessary to do
tuning. Demo of the map extraction done on NISSAN Micra.
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Week 4
During week 4 interns have involved in mounting the roll-cage, assembling the interior and exterior
parts, assembling the engine back to car. To overview the rally and building the car, idel racing from bangaluru
has brought the rally build Esteem, students had the opportunity to discuss with the team on tuning done on
the vehicle and ECU maps, suspension modifications and adjustments. Team have let the opportunity for few
students to sit on the co-driver seat to experience few rally driving modes.
Roll-cage installation
Tube bending is done using CNC bending process, team of students visited facility at peenya with 1:1
scale prototypes. During the bending, settings for bending, bend angles, die radius and requirement of the
bending were taught.
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Interns have finished the mounting of roll-cage, assembling the engine, exterior and interior parts and
suspension. Built up rally car has been driven for functionality.