virtual baja 2015_16116_team a.t.o.m_presentation
TRANSCRIPT
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