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BEANT COLLEGE OF ENGINEERING & TECHNOLOGY, GURDASPUR
(GOVT.)
TEAM ID : 16190
SPECIFICATION VALUES
Overall Length 2447.20mm
Overall width 1828.80mm
Front track width 1470 mm
Rear track width 1550 mm
Wheel base 1850 mm
Ground clearance 297 mm
Wheels- Front & rear
22*12*7 & 22*12*10 inches
Maximum speed 55.6 km/hr
Maximum acceleration
7.4 m/s²
Gradabilty % 86.5 %
Stopping distance 19.4 m (40 km/hr)
Kerb weight 190 kg
Ratio FAW & RAW 45:55
OVERALL VEHICLE DETAILS
Materials AISI 1018 AISI 4130 AISI 1020
Availability 4 3 2
Strength 3 4 4
Cost 4 2 3
Weight 3 4 4
Total 14 13 13
Material used AISI 1018
Yield strength 365 MPa
Tensile strength 440 MPa
Elongation 15%
Outer diameter 25.4 mm
Wall thickness 3 mm
Over all length 2083.6 mm
Max. width 718 mm
Weight 54 Kg
Material selection
Ergonomics Related to Cockpit :• Cockpit is designed in such a way that driver can exit within 5 seconds in an emergency .• RRH is given an angle of 15 deg. To give a good sitting posture to the driver. • Front bracing members are adjusted in a such way to give a wider view of vision. • Side impact members are designed to protect the driver from external threats.
Carbon 0.18 %
Iron 98.8 %
Manganese 0.6 %
Sulphur 0.05 %
Chemical Composition :
Welding used for the manufacturing of the roll cage is MIG welding .Due to its lesser cost and good strength .
Front impact force - 24000 N (8.6G )Max. stress - 184 MPa Deformation - 3.227 mm Factor of safety – 1.98
Rear impact force - 24000 N (8.6G)Max stress -293 MPa Deformation – 3.06 mm Factor of safety - 1.24
Roll over force - 2774 N (1G )Max stress – 157 MPa Deformation – 6.4 mmFactor of safety - 2.32
Side impact force - 11928.2 N (4.3G) Max stress - 302 MPaDeformation – 3.9 mm Factor of safety - 1.21
Parameter
Case I
Case II
Case III
Size of Mesh (Units)
20 10 8
No. Of nodes 219584 434629 485534
No. of Elements
133446 236481 253079
Max value of Von-Misses Stress (MPa)
225.62 285.89 290
Percentage Error
52.27 29.31 1.8
So we have selected the mesh size = 8 Because its Percentage error is less than 5 % after performing iteration .
SUSPENSION DESIGNType of Suspension (Front And Rear) - INWARD CONVERGING TRANSVERSE DOUBLE WISHBONE
CHARACTERSTICS FRONT REAR
GROUND CLEARANCE (m)
.297 .315
ROLL CENTER HEIGHT (m)
.231 .281
CAMBER (deg) -1.21 -1.50
CASTER (deg) 3.18 3.18
KPI (deg) 12.53 3.18
MOTION RATIO .8 .9
WHEEL RATE (N/mm) 9.645 15.612
SPRING STIFFNESS (N/mm)
15.07 19.274
NATURAL FREQUENCY (Hz)
2.41 2.46
RIDE FREQUENCY (Hz) 1.96 2.27
ROLLSTIFFNESS(Nm/deg)
202.54 327.15
CG Height (m) – .505Scrub Radius (m)- .067Sprung mass (kg) – 204Unsprung mass (kg)- 76
Material Used – 4130MAX . VON MISES STRESS-175MpaFOS-2.62
Material Used- 4130MAX. VON MISES STRESS- 148MpaFOS- 3.1
Bump travel (front)- 7inchBump travel (rear)- 6inchDroop travel (front)- 5inchDroop travel (rear)- 4inch
BRAKES
Disc Brakes
X-split brake circuit with master cylinder of Maruti 800 Bosch tandem cylinder (OEM) having bore diameter ¾ Inch and piston area of 0.4393 sq. Inch.
Discs of Maruti Zen is used for front wheels and TVS Apache RTR 180 is used for rear wheels and calliper of
respective discs are used.
For Brake fluid DOT 3 is taken.
SPECIFICATIONS VALUE
FRONT DISC DIAMETER 182mm
REAR DISC DIAMETER 270mm
FRONT CALLIPER PISTON 50mm
REAR CALLIPER PISTON 32mm
BRAKE FORCE 2058N
PEDAL FORCE 70lbs
DECELERATION 7.35m/s²
PEDAL RATIO 6:1
FRONT BRAKING TORQUE 189.04Nm
REAR BRAKING TORQUE 280.36Nm
CALLIPER PAD FRICTION COEFFICIENT(FRONT WHEEL)
0.08
CALLIPER PAD FRICTION COEFFICIENT(REAR WHEEL)
0.29
SPECIFICATIONS VALUE
FRONT CLAMPING FORCE 12.86KN
REAR CLAMPING FORCE 3.548KN
CYLINDER PRESSURE 6.59MPa
MEAN BRAKING RADIUS 91.85mm
WEIGHT TRANSFER 552.814N
STOPPING DISTANCE 19.4m(40km/hr)
STOPPING TIME 1.75s(40km/hr)
STEERING SYSTEMOver steerAckerman % - 80
Steering angle -inside - 40.51 (deg.)outside - 26.98 (deg.)
Turning circle radius – 2901.2mm
STEERING GEAR – R & P RHD (MARUTI SUZUKI 800)Rack travel – 120mmTurns lock to lock, rev. – 3.25
Steering ratio – 12:1OBJ center distance - 110mm
Length of Tie rod – 397mmLength of steer arm – 86.9 mmSTEERING COLUMN CollapsibleWithout power assist
LOTUS STEERING ANALYSIS
Steer Toe Ackerman Turning circle Travel angle (%) radius
(mm) {SAE} (mm)(deg.)
45.00 38.00 81.70 2979.5530.00 22.70 71.53 4955.3915.00 10.57 67.35 10418.210.00 0 66.16 0-15.00 -9.62 67.35 10418.21-30.00 -18.63 71.53 4955.39-45.00 -27.25 81.70 2979.55
STEERING WHEELSteering wheel diameter -390mmSteering wheel torque – 58.5Nm
Wheel Geometry
POWER TRAIN
• ENGINE SPECIFICATIONS
• Briggs and Stratton
• 305CC
• 10HP
• 19Nm at 2800 rpm
Overall gearratios
Tractiveforce (N-m)
Maximum velocity km/hr
Maximumacceleration m/(sec) ²
Gradability %age
37.5:1 2294 9.4 7.4 86.5
25:1 1529 13.5 4.7 57.6
12.5:1 764.6 28.2 2.0 28.8
6.25:1 382 55.6 0.6 14.4
• TCVT= 14.5 lb-ft * (12 in/ 1 ft) * (3/1) * 0.83 = 433 in-lb =48.9Nm
• Factor of safety for shaft is 4
• For tire diameter =22inch the maximum velocity attained by vehicle is 55.6 km/hr• N= Transmission efficiency = 0.85• Torque on the wheel=420ft-lb = 569.4Nm• 12.5:1 Gearbox is used
• TRANSMISSION : CVT COUPLED WITH MAHINDRA ALPHA GEAR BOX
• LAYOUT OF ENGINE , CVT AND GEAR BOX
COST ANALYSIS & WEIGHT DISTRIBUTION
26.50%
20.50%19%
6.30%
12.60%
15.14%
COST ANALYSIS
POWERTRAIN
SUSPENSION& STEERING
ROLL CAGE
BRAKING
WHEEL TIRE
SAEREGISTRATION
24.28%
19.28%
19.40%13.92%
23.00%
WEIGHT DISTRIBUTION
TRANSMISSION &BRAKING
SUSPENSION &STEERING
ROLL CAGE
WHEEL &TIRE
DRIVER
PROJECT PLANNING
Part Function Failure Models Precaution Validation Accomplishment
Roll Cage Basic Soul Of Vehicle And To Protect The Driver
When MaterialReaches To Ultimate Stress Value.
Use Of AISI 1018 Steel Having Yield Strength Value Equal 370 Mpa.
Welding Test Universal Testing Machine
ENGINE To Generate Power
Spark Plug Failure/ImproperFunctioning Of Old Filters.
Regular Check Of Spark Plug & FilterChange.
Fuel Leak Test
Vehicle Should Be Tested In Various Road Condition
TRANSMIS-SION
To Transmit Power From Engine To Wheels
ImproperLubrication/Unexpected Load.
Use Of ISO Grade Oils .
Speed And AccelerationTest
Road Test
SUSPENSION To AbsorbsShocks And To Give A Smooth Drive
When Coil Reaches To Solid Length.
Proper Calculation And Assumption In Designing.
Wheel Travel Inch Tape
BRAKES To Reduce The Speed When Required And Emergency Stop
Circuit Failure Due To Leakage Worn Out Break Pads.
Bleeding Of Vehicle’s Break Before Every Run, Checking And Replacement.
Breaking Test Road Test
WHEELS To Provide Good Traction
Inappropriate AirPressure/Puncture Tire.
Checking Of Air Pressure At Every Refuel Backup Extra.
Tire Air Pressure
Air Pressure Gauge
DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN
TEAM COMPOSITION & COLLEGE FACILITIES
TEAM STRATEGY FACULTY ADVISOR : SANDEEP GANDOTRA
DEPARTMENTS TEAM MEMBERS
1. ROLL CAGE ARSHDEEP SINGH, AMAN RANA,VINAY KUMAR (Captain) ,LOVY MINHAS, SAEED AKHTAR, SACHIN, SATNAM SINGH
2. TRANSMISSION ANUJ BHARDWAJ, SHIVAM BHARDWAJ,AMARJEET GULERIA, NAVJEET SINGH, KASHISH MAHAJAN, RAKESH ,SHAMSHER SINGH,VARUN SHARMA
3. SUSPENSION ANSHUL SHARMA, ABHISHEK THAKUR, VINAY KUMAR, ANUBHAV MAHESHWARI, ABHINAV KUMAR, NITISH PANDEY, SATISH
4. BRAKING GAGANDEEP SINGH, ANUJ BHARDWAJ
5. STEERING AMAN RANA, ARSHDEEP SINGH, AMARJEET GULERIA
6. DRAFTING & ANALYSIS
KRISHNA KHOSLA,JATIN SARINE
7. MANAGEMENT ANUBHAV MAHESHWARI,SHAMSHER SINGH,UTKARSH
COLLEGE FACILITIES
For Roll Cage , Each and every equipmentavailable in welding shop.
For Custom Knuckle , requirements areavailable in Carpentry , Foundry and machineshop.
For Seat Installation and Sheet Covering ofvehicle , equipments are available in weldingand sheet metal shop.
For clamping of Wishbones , each and everyrequirements are available in Central Workshop.
For Assembly and Installation of all other partsof vehicle, requirements are available in CentralWorkshop.