TEAM GEAREDUP - 96745 19th AUGUST 2011

DKTE’S Textile and Engineering Institute,IchalkaranjiKolhapur.

SAE BAJA - 2012

Team CaptainSaddam Hussain(B.E. Mechanical)

Faculty AdvisorProf. Mr. A. R.

Balwan

RULE BOOK IMPORTANT PARAMETERSPARAMETER ALLOWED SELECTED

TRACK WIDTH 64 INCH 46 INCH

WHEEL BASE 108 INCH 67 INCH

MAXIMUM SPEED 60 Km/Hr 45 Km/Hr

MATERIAL STRENGTH 365 Mpa 480 Mpa

DRIVER HEAD CLEARANCE

6 Inch 6 Inch

VEHICLE MUST BE SAFE AND EASY TO RIDE. EASY ACCESSIBLE COCKPIT. AESTHETICALLY GOOD . VERY LESS UTILISATION OF READYMADE COMPONENTS. NO ALTERATION WITH THE ENGINE. DRIVER SHOULD BE EQUIPPED WITH SAFETY GEARS AND

MEASURES. PROPER FUEL STORAGE WITH DRAINAGE SYSTEM. INDEPENDENT BRAKE CYLINDERS FOR FRONT & REAR

WHEELS. PROPER & SAFE CLEARANCES.

CHASIS…DIMENSIONS: Length= 87 inch Height= 48 inch Width= 33.02 inch At front end= 13.4 inch At rear end= 15 inch

MATERIALS: Steel IS 1239

WEIGHT:

WEIGHT APPROX. :- 68 KG

PURPOSE : Material -- High yield strength and cost which is moderate. Roll Cage – Simple design will lead easy manufacturing with future modifications and effective utilisation of space.

ADVANTAGE : More space for the driver to easily enter and exit the vehicle. Suitable for long and bumpy terrains.

Side impact members –BENDED- More space & clearance between the member and knees for SAFETY.

OUTER DIAMETER: 33 mmTHICKNESS : 3 mm

ERGONOMIC AND AESTHETIC VALUES

SPACIOUS COCKPIT COMFORTABLE HEIGHT & INCLINATION OF STEERING

WHEEL SMALL WHEELBASE FOR EASY MANEUVERABILITY. SIM (SIDE IMPACT MEMBER) MODIFIED FOR INCREASING

COMFORT OF THE DRIVER. SIM

WHOLE WEIGHT OF CHASIS SUPPORTED OVER 2 PARALLEL L-CHANNELS. INCLINATION OF 6 DEG. AT FRONT END OF LFS – NATURAL WHEEL

TRAVEL DURING FRONT HUMP ENCOUNTER. EVERY PART HAS BEEN DESIGNED UNDER APPROPRIATE PROPORTION. WELD JOINTS REPLACED WITH BENDS TO ENHANCE STREAMLINE

EFFECT.

L-CHANNEL

FRONT

TOP

SIDE

6 Deg

FEA RESULTS & CONCLUSIONLOAD INFORMATION

FRONT IMPACT AT FULL SPEED OF 60 Km/hr.

MESH INFORMATION

FEAFRONT IMPACT SIDE IMPACT

OTHER PARTS…

REAR ARM FRONT A-ARM

FRONT HINGE REAR HINGE

FRONT VIEW SIDE VIEW

ISOMETRIC VIEW TOP VIEW

48 inch

66.8 inch

46 inch

12 inch

TRANSMISSION

GEARBOX : MAHINDRA & MAHINDRA ALPHA CHAMP Having 4 forward + 1 reverse gear with built in differential and universal joint .Configuration of our vehicle would be REAR ENGINE REAR WHEEL DRIVE CALCULATIONS :

ENGINE SPECIFICATIONS: Lombardini LGA 340

Rated Power: 8 kW at 4400 rpm Max Torque: 19 Nm at 3000 rpm

TYRES : WHEELS :DIAMETER 24 INCHES , WIDTH – 12 INCH R15-SKODAATV TIRES

1ST - 6.8 TO 10.06 Km/hr2ND -11.55 TO 16.94 Km/hr3RD - 18.94 TO 27.78 Km/hr4TH - 29.38 TO 43.10 Km/hrREVERSE – 3.92 TO 5.75 Km/hr

BRAKESREAR : Internal Expanding Shoe BrakesFRONT : Disc Brakes

Weight falling on each rear wheel 48 kg

CHARACTERISTICS

Independent Hydraulic reservoirs

Four wheels must lock at the same time.

Produce required force to stop the vehicle at the maximum speed.

SR NO.

V

(km/hr)

R F(braking)

(N)

f(deceleration)

(m/s2)

1. 50 1 808.525 2.99

2. 50 .55 1281.86 4.74

3. 50 .45 1473.56 5.45

4. 50 .40 1593.66 5.89

5. 50 .35 1899.73 7.03

SR. NO. V(Km/hr) f (m/s2) R – R’(N) S(m)

1. 50 2.99 290.63 32.26

2. 50 4.74 460.73 20.35

3. 50 5.45 529.74 17.7

4. 45 4.74 460.73 16.48

5. 45 5.45 529.74 14.33

6. 45 7.03 683.32 11.11

7. 35 5.45 529.74 8.67

8. 35 5.89 572.51 8.02

9. 35 7.03 683.32 6.72

SUSPENSIONSUSPENSION DEMANDS: Ground clearance to be 11-12 inches

PARAMETER

spring rate 19.71 N/mm

Total number of coils

15.00

Number of active coils

13.00

Wire diameter 11.00 mm

Free length 390 mm

solid length 150 mm

solid load 4827.22 N

FIGURE FROM SUSPROG SOFTWARE

TYPE- 14” Rack and Pinion systemRACK C- FACTOR - 52.00STEERING RATIO- 12.10

TURNING RADIUS- 3.6m( tire contact centre) LH/RH

STEERINGFor steering calculations we used Susprog software

SR . NO. A(degree) L1(inch) r 1(m) L2(inch) r 2(m)

1. 30 70 22.07 60 18.9

2. 45 70 14.72 60 12.62

3. 60 70 11.04 60 9.47

4. 90 70 7.37 60 6.32

5. 120 70 5.54 60 4.75

6. 135 70 4.93 60 4.22

7. 150 70 4.44 60 3.81

8. 210 70 3.19 60 2.74

9. 240 70 2.80 60 2.40

10. 300 70 2.26 60 1.94

11. 360 70 1.91 60 1.63

ELECTRICAL SYSTEMS IGNITION SWITCH 12v 44Ah BATTERY HORNS

TAIL LIGHT HEAD LIGHT

ENGINE MOUNTING Lombardini LGA 340

C-CHANNELS WITH HOLES ENGINE MOUNTING

BOLTING FINALISING

DFMEA

INNOVATIONHYDRAULICALLY & COIL SPRING OPERATED VARIABLE

SUSPENSION SYSTEM OIL TANK

OIL PUMP OIL PUMP

OIL TANK

OIL CYLINDER

OIL CYLINDER

NORMAL MODE OPERATIVE MODE

IT PROVIDES OVERALL VARIABLE STIFFNESS TO THE SUSPENSION SYSTEM.

HELP TO INCREASE/DECREASE GROUND CLEARANCE. EASES THE DRIVER WHILE DRIVING AROUND A RADIUS.

DESIGN VALIDATION PLAN

RELIABLE AND SAFE

SR.NO.

COMPONENT

PROPERTY TEST VALIDATION

1. Chassis welding Destructive testing

Comparing the stress level obtained with permissible

level for the given material.

Dimensions Measuring Manually

Rechecking and comparing with 3-D model

2. Brakes Pedal Position

Trials to be carried

out

Suitable for both of our drivers.

Brake force Trial on vehicle

Safe and short stopping distance.

3. Steering Wheel position

Trial on vehicle

Comfort to the driver

Maneuverability

Static test Degrees of turn of tires per degree of rotation

of wheel.

4. Transmission Engine mounting

Test for Vibration

Centre position & less vibration.

Axle length Trial Compare with standard assembly.

PROJECT PLANSR NO. TASK DEADLINE

1 STUDY OF RULEBOOK 2ND Week of January

2 DATA COLLECTION 15 th Feb

INITIAL DESIGN 28th April

3 3-D MODELING 15th May

4 PDR 26th May

5 ANALYSIS 30th July

6 COST ESTIMATION 20th August

7 FINAL DESIGN 30th August

8 MARKET SURVEY 30th August

9 SPONSORSHIP 25th September

10 MATERIAL PROCUREMENT 20th October

11 FABRICATION AND ASSEMBLY 10th December

12 TESTING 10th January

13 FINAL DESIGN REPORT 20th January

RELIABLE AND SAFE

1. Ghorpade Abhijeet2 Vivek Mahajan3.Thombare Sagar4. Ashish Rajoba5. Siddhesh Yadav

1. Swapnil Babar2. Ajay Borate3. Akshay Rukhade4. Rahul patil5. Nityanand Khushwaha6. Hariom

1. Shahnawaz Tambe2. Mahesh Kale3. Katti Indrajeet4. Aniket Patil5. Thorwat Aniruddha

1. Saddam Hussain2. Indranil Banerjee3. Abhineet Badve4. Ashish Patil

TEAM STRUCTURE AND DISTRIBUTION

1. Saddam Hussain (captain)2. Pranav Kawre3. Pankaj Salgare4. Kulkarni nilesh5. Chetan Bhupal

COLLEGE FACILITIES-HIGHLY EQUIPPED WORKSHOP - CNC Machines -Drilling Machines

- Milling Machines - Lathes

- Sheet Metal Bending Machine - Arc Welding

- Smithy shop - UTM

- CAD Lab-ADVANCED HOYT TRAINING LAB- LIBRARY- Books and Journals on Automobile.- INTERNET + 24 hr Wi-fi - SEPARATE SPACE FOR SAE BAJA VEHICLE FABRICATION.

SAFETY•PRECAUTIONS TAKEN :

• A five point restraint harness • Single metal‐to‐metal quick release lever type

buckle• Engine Shield.• Seat Belts as per the rule of SAE• Avoid breaks in the Design of Roll- cage.• Helmets and fire-proof suite.• Fuel spill-drip pan.• Fire-resistant roll- cage padding.• Separate master cylinders for braking system.• Avoid or remove sharp edges or burrs.