SUPRA SAEINDIA 2015VIRTUAL PRESENTATION

SRI VENKATESWARA COLLEGE OF ENGINEERING

SRIPERUMBUDUR, TAMILNADUTEAM SPARK RACING

TEAM ORGANISATION CHART

TEAM CAPTAINASHWIN KUMAR

VICE CAPTAINDHAMODHARAN

TREASURERSIDDHARTH

BUSINESS PLANNING& MARKETING

ISHAAN CHANDOKASHWIN SRI HARI

ARUNESHWAR

STEERING

KAMALAKANANGNANAPRAKASH

ABILASH

ELECTRICAL WIRING& HARNESS

SIDDHARTHBALACHANDER

JERRY PRASHANT

BRAKES

VISHAAL KRISHNA SUDHAN PRASHANT

SUSPENSION

SATHISH KUMAR ASWIN DHANANJAI KUNAL.K.DAVEY

YOGEENDRAN

ENGINE&DRIVETRAIN

GURUBHARGAV

BALASUNDAR

Department leader

Department leader

Department leaderDepartment leader

Department leader

Department leader

Department leader

FACULTY ADVISOR

Mr.K.PAUL DURAI

RULEBOOK COMPLIANCES.NO RULES DESIGN CRITERIA OUR DESIGN

1 Engine Lesser than or equal to 610 cc 373 cc

2 Wheelbase Greater than or equal to 1525 mm 1549.6 mm

3 Air flow restrictor in intake manifold Diameter of 20 mm 20 mm

4 Vehicle Frame

Vehicle structure must include 2 roll hoops that are braced, a front bulkhead with

support system, impact attenuator and side impact structure.

Followed

5 Driver ViewMust have a minimum field of vision of

200 degrees by turning head or by the use of mirrors.

Obtained angle 221°

6 Suspension When the driver is seated the wheel travel must be atleast 50.8 mm. 51 mm

7 Wheel diameter Greater than or equal to 8 inches 13 inch

8 Braking system Single control, 2 independent hydraulic circuits

Single control, Parallel circuit hydraulic braking system

9 Ground Clearance No Part of the bottom side of the vehicle should touch the ground

Ground Clearance of the vehicle is 51.98 mm

10 Impact Attenuator Energy absorbing structure capable of absorbing greater than 7000 J Carbon fiber – 9310 J

OVERALL TECHNICAL SPECIFICATION & PERFORMANCE TARGET

SPECIFICATIONS OF THE CAR DETAILS

Engine Used Single cylinder, four stroke,373.2cc

Overall DimensionWheel base

2780X1143X1093 mm1575 mm

Vehicle body Tubular space frame with light weight fiberglass panel

Suspension type Double A-arm push rod actuated

Steering system Self designed rack and pinion type system

Brakes Parallel hydraulic actuated floating disc brakes

Wheels & tyres 13 X6 inches Alloy wheels and 20.5X6 inches tyres

PERFORMANCE TARGETS: To achieve the followingReal Time accomplishment of calculated design Weight reductionHigh Power/Weight Ratio High Acceleration High Stability High acceleration

PROJECT GANTT CHART

COMPLETED

PROJECTED

EVENTS

WE ARE HERE !!!

ERGONOMICS

Ergonomic features Details

VisibilityGood range of 221° by turning the headAnalogue display gauge above steering wheel below second roll hoop for better visibility

95th percentile compliance in ergonomics

Ergonomic posturesKnee angle - 150°Foot angle - 95° (When pedal disengaged)Head room clearance- 55.54 mmShoulder harness- 0° to 10° below shoulder

Cockpit

Designed for quick ingress & egress, achieved through low side member heightSeat thigh support to reduce fatigue while operating pedals

Safety within driver’s reach

Kill switchesFire extinguisher

Detachable components

Steering wheel (Quick release mechanism) Driver seat

DESIGN METHODOLOGY FOR ROLL CAGE

MATERIAL CHOSEN FOR ROLL CAGE SAE 4130 – ‘CHROMOLY’

METHODOLOGY

Setting dimensions as per rulebook Tubular steel space fameMaterial selectionDesign of rollcage with proper triangulated joints and rule book templates Design to achieve high factor of safetyAnalysis of weak points and optimization

ANALYSIS TYPE 1D structural and modal analysis of roll cage

SOFTWARE USED ANSYS 15

FINITE ELEMENT ANALYSIS-ROLL CAGEFRONT IMPACT DEFLECTION REAR IMPACT STRESS

SIDE IMPACT STRESS TORSIONAL STRESS

ANALYSIS LOAD(N)CONSTRAINTS

Degrees of freedom arrested

DEFLECTION(mm) F.O.S

Front Impact

8829(3g)

FSM-Vertical TranslationRSM-3 Translation

0.469 6.18

Rear Impact

8829(3g)

FSM-3 TranslationRSM-Vertical Translation 0.71 4.13

Side Impact

8829(3g)

All lower Suspension Mounting points are arrested

in all 3 translation6.079 2.16

Roll Over

8829(3g)

FSM-Vertical TranslationRSM-3 Translation 1.24 4.21

Torsional 17658(6g)

RSM-All 3 translationFSM- Free

19 1.78

• Torsional rigidity – 6455 Nm/deg • Bending Stiffness- 1536 N/mm

•Modal Analysis of roll cage at 10th mode is 128 Hz.

INFERENCE :`

COMPONENTS LOADS CONSTRAINTS (DOF ARRESTED) δ(mm) F.O.S

Front Hub3g-Vertical &

horizontal1g Axial(lateral)

Wheel mounting pts – All 3 translation 0.05 3.89

Rear hub Same Front hub load &Driving torque Same as front hub 0.04 5.22

Disc Mounting Plate Braking force Hub mounting pts – All 3

translation 0.02 2.56

Front Upright3g-vertical &

horizontal1g-axial(lateral)

Bracket mounting pts – All 3 translation 0.007 4.9

Upper Bracket Same as front upright A-arm & tie rod mounting points- All 3 translation 0.032 3.33

Lower Bracket Same as front upright Same as upper bracket 0.032 2.42

Rear Upright Same as front upright A-Arm Mounting Points – All 3Translational DOF. 0.008 1.8

Caliper bracket Braking force Upright mounting pts –all 3

translation 0.058 1.89

COMPONENTS MATERIAL CONSIDERED

WHEEL HUBS Steel (SAE 4340)

WHEEL UPRIGHTS Aluminium(Al 6061 T6)

HUB &UPRIGHTS

Hub Analysis

Upright Analysis

ExplodedView

SUSPENSION

Suspension type Double A- arm push rod activated suspension

Methodology

•Anti dive and Anti squat were considered in the design.•FVSA and SVSA geometry were used to determine roll centre, instantaneous centre and mounting points.

•Good Camber gain was achieved using linkarm design diagram

Consideration for selectionOf Materials

•Springs and Dampers

•Based on requirements, costs and availability

Roll center Front = -30.78 mmRear = 37.05 mm

Camber -2°

Caster 8°

Scrub Radius 24 mm

Roll Angle 2.5°

Toe-in 2°

Push rod suspension simulation using Hyperworks

Line diagram

Suspension

Material Used Carbon fiber

F.O.S Front = 2.5Rear = 2.98

STEERING

CREO MECHANICA- PROPOSED STEERING SYSTEMRACK & PINION EXPLODED VIEW

Steering system type used Rack & Pinion

Mechanism Ackermann mechanism

Degree of rotation (lock to lock) 210°

Rack Travel 75 mm

Turning Circle Radius 3.8 m

Steering gear ratio 3:1

35 35.5 36 36.5 37 37.5 38 38.5 39 39.5 401.800

2.300

2.800

3.300

3.800

INSIDE LOCK ANGLE (Ɵ) VS RADIUS OF CURVATURE

Rif = (b/sin θ) - ((a-c)/2) Rof= (b/sin φ) + ((a-c)/2) Rir= (b/tan θ) - ((a-c)/2) Ror= (b/tan φ) + ((a-c)/2)

INSIDE LOCK ANGLE (Ɵ)

RA

DIU

S O

F C

UR

-V

AT

UR

E (i

n M

eter

s)

ECU USED RACE DYNAMICS POWERTRONICS

FEATURESFuel mappingIgnition mappingHigh rev control

PROS

Increases powerImproves combustion efficiencyTop speed and better throttle response

KTM 390 RACING 373.2CC

Single cylinder throttle body injection

of 46mm diameterBetter power to

weight ratio Light weight 32 kg

SIX SPEED GEAR BOX

Performance 32kw(43hp)

TYRE

•HOOSIER – Slick tyre•Size : 20.5"x 6.0“ inches• Wider tyres for better traction

WHEEL

•Chrome plated alloy wheels, lighter & stronger•SIZE - 13"x6“ inches

QUAIFE ATB

FINAL REDUCTION

4:1

ChainDriven Torsen Type

Limited Slip Differential

POWERTRAIN & DRIVETRAIN

Engine Mounting

TOTAL LENGTH OF MANIFOLD 250mm(approx.)

CONVERGENCE ANGLE 14°

DIVERGENCE ANGLE 6°

CONSTRAINTS Inlet, Outlet and Restrictor diameter

TURBULENCE

Better Fuel-Air mixing

Minimal fuel evaporative loss

INLET CONDITIONS S.T.P

FORMULA USED TO DETERMINE MASS

FLOW RATE MFR: 0.035 kg/s

INTAKE MANIFOLD

STATIC PRESSURE TURBULENCE ENERGY

VEHICLE AERODYNAMICS- SHELL BODY

Air at 27.77 m/s (100 kmph)

Vehicle shell body

Wind tunnel flow simulation

Design Methodology Detail optimization

Boundary Conditions Inlet Conditions S.T.PAir Velocity 100 Kmph

Turbulent Intensity 10%

CONSIDERATION FOR BRAKE SELECTION

Hydraulic disc brakes(TVS-Apache)Size CostAvailabilityThree mounting points simplifying Hub design

DESIGN METHODOLOGY

Parallel Brake CircuitPetal disc shape for better heat dissipation

SPECIFICATION

Front Caliper & Rear disc –(TVS )DISC 200 mm petal discBrake fluid DOT-4Master cylinder

Caliper

BRAKES

Bore – 25.4 mm

Piston Diameter – 32mm

T-Joint

Brake

lineBrake disc

Master cylinde

r

Parallel brake circuit

BRAKES

Total weight ConsideredTotal calculated braking forcePedal ForceLeverage ratioBraking Efficiency

360 kg (including driver)3001.86 N

355.98N (36.28 kg) 4.67: 1 85 %

Design Validation

Static: Testing of reactions forces on each wheel (Calculation of C.G)Fluid Leak testElectric leak testing

Dynamic:

Engine dynamometerChassis dynamometer Chain rig test Noise level testIPG carmaker

DESIGN VALIDATION PROCESS

During this process the performance of each component is checked after assembling.

The vehicle performance is checked using a Chassis Dynamometer.

Necessary changes are made and the vehicle is tested On Road.

During Road Test process the vehicle is run over a series of tracks with lots of obstacles, tedious turns, different tractive surfaces.

Finally the Endurance test is performed.

FACILITIES AVAILABLE AT COLLEGE PREMISES

Name of the Facility Equipments/Mahine/Softwares

CAD / CAM LABORATORY Creo parametricAnsys 2015Mathlab worksIPG carmaker

MACHINE SHOP Hydraulic Pipe Bender Centre Lathe CNC Lathe – LMW Milling Machine

(Universal & Vertical) Gear Hobber Grinder (Pedestal, Surface

& Cylindrical) Shaper and slotter, Planer Power Hacksaw machine Radial Drilling Machine Tool and Cutter Grinder

WELDING RESEARCH CELL

TIG, MIG, Arc and Gas Welding

AUTOMOTIVE COMPONENTS TESTING LABORATORY

Chassis Dynamometer Engine Dynamometer Wheel Alignment

Equipment Suspension Test Rig Chain Test Rig

EQUIPMENT RATING

Driver Restrain System

TRS Magnum 6 Point Harness MH460-100—FIA 8853/98

Helmet OMP GP7K Helmet—Snell SA 2010

Driver Suit OMP Sport Race Suit-FIA 8856-2000

Padding SFI 45.1

Shoes OMP First S Race Boots-- FIA 8856-2000

Arm Restrain SFI 3.3

Fire Extinguisher Powder extinguisher homologated by the FIA

Driving Gloves, Neck

clothing, Balaclava,

Underclothing

SFI Rated Nomex

DRIVER SAFETY EQUIPMENTS

COST REPORT & SPONSORSHIP DETAILS

SPONSORSHIP DETAILS

SRI VENKATESWARA COLLEGE OF ENGINEERING BAJAJ KTM ST ADVANCED COMPOSITES CHENNAI SILKS

MAGNA ENTERPRISES SATTVA LOGISTICS PVT LTD TAMILNAD TRADERS SIMULINK (MATLAB) IPG FORMULA CARMAKER

Pie Chart Code Department Total Cost

(in  )₹

RC Roll cage 90,000

EE Engine & ECU 1,15,000

DT Drivetrain 1,10,000

BS Braking system 45,000

ST Steering System 50,000

SS Suspension System 1,20,000

WT Wheels & tyres 95,000

EW Electrical wiring 30,000

SE Safety equipments 1,00,000

FF Miscellaneous Fits & finish 40,000

Total 7,95,000

Source of Income Amount (in )₹Students 5,00,000

College fund 1,50,000

Sponsorship 2,00,000

Total 8,50,000

RCEEDTBSSTSSWTEWSEFF

TEAM SPARK RACING THANKS YOU !!!