ITM University, Gurgaon

Outline of presentation
1. 2. 3. 4. RULEBOOK AND ITs CONFIRMANCE COLLEGE FACILITIES TEAM DETAILS DESIGN VALIDATION
FRAME DESIGN AND ANALYSIS SUSPENSION VALIDATION STEERING VALIDATION BRAKE VALIDATION

5. AIRFOIL AND NOSE DESIGN ANALYSIS 6. 3-D MODELLING 7. DRAFT TECHNICAL SPECIFICATIONS 8. INNOVATION 9. PROJECT PLAN 10. COST REPORT 11.TEAM SPONSORS

RULE BOOK CONFIRMANCE

SUSPENSION STEERING
Wheel travel of at least 50.8 mm , with driver seated. The steering wheel must be mechanically connected to the front wheels Minimum static ground clearance = 25.4 mm

Wheel travel is taken M800 Rack and Pinion as 79 mm with driver seated. Ground clearance under static load = 63.5 mm

BRAKES FRAME AND WHEELS

Brake system must act on all four wheels & The car is equipped with diagonal hydraulic linkage , Front and Main Roll Hoops =38 x 2.4 mm, 40 x 2 mm The brakes used will be disc brakes on all four tires 40 x 2 mm controlled by single pedal. 9.3inches diameter. Side Impact Structure, Front Bulkhead, 25.4 x 1.65 mm of25.4 x 2.5 mm Front Bulkhead Support , 25 x 1.5 mm

Shoulder Harness Mounting , 25 x 2.5 mm Engine used is M-800 BS-3 MPI Engine with Front bulkhead support, side impact bracing, Transmission . 25.4 x 1.5mm
Roll Hoop Bracing, 25.0 mm x 1.75 mm

ENGINE AND TRANSMISSION

25.4 x 2 mm

AIRFOIL

25 x 2.5 mm Engine used is M-800 BS-3 MPI Engine(sponsored) 25.4 x 1.5 mm Transmission is inclusive with the engine. 4 forward +1 reverse manual gearbox 25.4 x 2 mm
Alloy steel AISI 4130 with carbon content The airfoil we have designed have radius of 12.7 0.28-0.33 mm (0.5 inch)

The material for the primary structure have to be All wing leading edges must have a minimum Round, mild or alloy, steel tubing (minimum 0.1% radius 12.7 mm (0.5 inch) carbon)

Wheelbase of at least 1524 mm (60 inches). Wheelbase of the vehicle-1778mm(70inches) In plan view, no part of any aerodynamic device, In plan view, the airfoil is 430 mm forward of the The smaller trackor splitter can be furtherrear) <= 75% front the tires. track width is1295 mm and larger is The smaller wing, under tray of the vehicle (front or forward of the larger track.inches) forward of the fronts of the 1320.8mm, which is 98% of the larger track. than 460 mm (18 front tires The wheel size must be 8 inches or more in diameter 145/70 R-12

Engine Testing

Power Hacksaw

Engine (Cross Section)

Facilities available in our College

Bench Drill

Universal Testing Machine

MIG Welding

Lathe M/C

CNC Machine

Hand Grinder Milling M/C Shaper

Hi-tech CAD labs

Power Mill

Forging Bench

TEAM DETAILS
S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 NAME JATIN GOEL PRABHAT TIWARI GAURAV SAINI KARAN MAHAJAN SUMIT CHOPRA HIMANSHU GUGNANI GAUTAM CHABRA LAKSHAY GANDHI KARTIK KHURANA YOGANSHU KAKKAR NITIN RANA ABHISHRESHTH DESWAL AKSHAY VASHISHTA KANCHAN VASHISHT SANCHIT TONDAN ISHU JAIN ANKIT DHIMAN SWATI MEHNDIRATTA KARAN BHARDWAJ ABBHIYANK GOVIL DHRUVAY JAIN SIDHARTHA JAITLY LOKESH MITTAL MOHIT GREWAL VIKAS SHARMA VINKEL ARORA SAE No. 7110323493 7110323473 7110323336 7110323498 7110323487 7110323345 7110323340 7110323357 7110323500 7110323458 7110323471 7110323491 7110323496 7110323480 7110323405 7110323410 7110323313 7010310708 7110323499 7110323302 7110323501 7110323423 7110323472 7110323363 7110323451 7110310057 DEPARTMENT DESIGN ( TEAM CAPTAIN ) DESIGN BRAKES+TYRES+WHEELS BRAKES+TYRES+WHEELS BRAKES+TYRES+WHEELS BRAKES+TYRES+WHEELS STEERING+SUSPENSION STEERING+SUSPENSION STEERING+SUSPENSION STEERING+SUSPENSION POWERTRAIN POWERTRAIN POWERTRAIN FABRICATION FABRICATION FABRICATION FABRICATION FABRICATION FABRICATION COST+PROCUREMENT COST+PROCUREMENT ELECTRICALS MARKETING MARKETING MARKETING FACULTY ADVISOR

DESIGN VALIDATION
FRONT VIEW ISOMETRICVIEW SIDE VIEW TOP VIEW

Views of Frame

FRAME material
SOFTWARE used: SOLIDWORKS and ANSYS 12. Material: ALLOY STEEL (AISI 4130).
MATERIAL C% Mn% Si% AISI 4130 0.28-0.33 0.4-0.6 0.15-0.35

S%
Mo% Mn% Fe% P% Yield Stress Tensile Strength

0.04 Max
0.15-0.25 0.60-0.90 97.3-98.2 0.035 Max 435 MPa 670MPa

FRAME DESIGN ANALYSIS

FRONT IMPACT :
In Front impact test, it is assumed that two bodies moving in opposite direction collide head on. Max. Stress Induced = = 1.5MPa Max. Displacement 224 mm Force of Impact = 26249.4N

The following tests were done on the frame:

FRONT IMPACT REAR IMPACT ROLL OVER IMPACT SIDE IMPACT

10 SIDE IMPACT REAR IMPACT ROLLOVER IMPACT The force used for roll over analysis is dependent on the weight of the on its In this type of impact, a body will hit to the frame of the vehicle vehicle and center of gravity location be: its side. The force encountered will rear. The force encountered will be: In analysis we consider 3gN Impact Force = 13122 effect :

Force calculated on front hoop = 8343 N Force calculated on main hoop = = 224.2 N mm Max.Max. Displacement = 3.21 Stress Induced 13230 MPa

Max. Stress Induced = = 2.53mm Max. Displacement 252.1 MPa Max. Stress Induced= 5.37 mm Max. Displacement = 353.4 MPa

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SUSPENSION VALIDATION
Validation of Spring Design by IST Spring Design Software

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Rear Suspension Geometry Front Suspension Geometry KINEMATIC MODEL

KINEMATIC MODEL Front Suspension
STATIC CAMBER STATIC CAMBER CAMBER GAIN IN JOUNCE CAMBER GAIN IN JOUNCE -1.0 -1.0 -0.06/1" -0.81/1"

CAMBER GAIN IN REBOUND 0.34/1" CAMBER GAIN IN REBOUND 0.62/1"

Kinematic Model KINGPIN INCLINATION KINGPIN INCLINATION

SCRUB RADIUS SCRUB RADIUS TOE IN TOE IN GROUND CLEARANCE GROUND CLEARANCE STATIC ROLL CENTER STATIC ROLL CENTER FRONT TRACK WIDTH FRONT TRACK WIDTH

CASTER CASTER

5 5
1 3 1.332" 1.02" 1 0 5" 3" 2.5" 3.5" 52" 52"

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ANTI SQUAT ANTI DIVE

The geometry is designed so the frontcontrol arms absorb approximately 40% The geometry is designed so the rear control arms absorb approximately 40% of the longitudinal force due to acceleration. This iskeep the the suspension to of the longitudinal force due to braking. This is to to keep suspension from travel in condition of bump during acceleration. a bump at the same time bottoming out when braking and possibly hitting

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STEERING VALIDATION
Due to the light weight, low cost and simplicity of Rack & Pinion, we will use Maruti-800 Rack and Pinion

Kinematic Model

Specifications of Steering
No. of teeth on pinion = 6 No. of teeth on rack = 24 Rack length = 137mm Rack Gain = 34.1504mm Placement of steering ahead of axle = 3 inches Steering ratio = 8.2

BRAKE VALIDATION
Braking system has Disc Brakes at both Front and Rear wheels Brake torque requirement Rotor, outer radii 118mm For front tires = 496.46 J For rear tires = 400.56 J
Inner radii 83mm
UNDER STATIC CONDITIONS

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PART Front Axle Rear Axle

STATIC LOAD 180kg 270kg

Braking Torque developed Placement outboard Torque developed at front = 768.3 J Torque developed at pistons= 533.2 J Caliper 2 rear

UNDER DYNAMIC CONDITIONS

Braking torque of 20mm by the brakes is more than the required Bore Diameter developed PART DYNAMIC LOAD Piston therefore this results in locking of all wheels
Front axle Here, friction radius 101.51mm Rear Axle 201 kg 249 kg

AIRFOIL DESIGN AND ANALYSIS

Chord length = 317.5 mm Length of airfoil = 1320.8mm Distance of airfoil from ground = 63.5mm Coefficient of Lift, Cf = -1.024 Coefficient of Drag, Cd = 0.0213 Downforce = 182.56N h/c ratio 0.075 0.15 0.2 Coefficient of lift -0.48 -0.52 -0.46 Coefficient of drag 0.018 0.012 0.0090

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0.35
0.5

-0.32
-0.25

0.0067
0.0055

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RESULTS
ANGLE OF ATTACK AIR VELOCITY (m/s) LIFT COEFFICIENT 3 7 9 10 11 12 13 14

29.16

29.16

29.16

29.16

29.16

29.16

29.16

29.16

-0.299

-0.61

-0.852 -0.858 -0.866 -0.886 -1.024 -1.082

COEFFICIENT OF .00034 .00676 .00784 0.0112 DRAG

0.014

0.0145 0.0213 0.0292

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COMPUTATIONAL FLUID DYANMICS OF NOSE

Coefficient of drag = 0.117 Coefficient of lift = -0.12

3D Model ling

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Detailed View

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DRAFT TECHNICAL SPECIFICATIONS

INNOVATIONS
Enhanced Acceleration & Signaling

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When the driver applies throttle, the system signals the attainment of 2500 rpm, this signal will guide the driver to release the clutch at a Max. torque, thus, achieving best possible acceleration by the vehicle. At 5000rpm(of engine) the system provides signal to the driver alerting him of achieving Max. Power which guides the driver in switching the gears more efficiently. Distance Proximity Assistance The Driver is assisted with a distance proximity device which alerts the driver when the vehicle has an approaching vehicle or an obstruction from a side using an alarm. The range of the device is 2m from the all sides of the vehicle. Thus, this provides an additional safety as well as an effective racing tool for the driver. Aerodynamic Brakes We are adding drag by varying angle of attack of the airfoil, to increase the effectiveness of braking system.

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TECHNICAL SPECIFICATIONS
Wheel Track(mm) Brake System Front Rear Front(Diameter,mm) Wheel Base(mm) Rear(Diameter,mm) Overall Length(mm) No. of pistons Weight of Vehicle(kg) Bore diameter of Weight Distribution Piston(mm) Ratio(front:rear) Friction Radius(mm) SUB-SYSTEM Steering System SPECIFICATIONS Suspension Engine & Transmission Front Company Type Rear Displacement(cc) Compression Ratio Tyres Torque Front & Rear Power Transmission Disc brakes on all four wheels with 1320.8 separate hydraulic system for front and 1295.4 rear brakes. 1778 118 2372 118 450 2 40:60 20 101.51 Maruti 800 Rack and Pinion Push rod , unequal wishbone Maruti Suzuki India Ltd. Gasoline(Naturally Aspirated) Double Wishbone with Helical Coil 796 Spring 8.6:1 to 9:1 59 N-m at 2500 RPM 145/70 26 KW at 5000 RPM R-12 4 forward + 1 reverse manual gearbox

PROJECT PLAN

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COST REPORT

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TEAM SPONSORS