CHRIST UNIVERSITY FACULTY OF ENGINEERING, … Internship... · department of mechanical engineering...

CHRIST UNIVERSITY FACULTY OF ENGINEERING, BENGALURU

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP PROGRAMME ON AUTOMOTIVE DESIGN AND DEVELOPMENT

Day : 1

Topics Covered for the Day: Date: 15-04-2015

1. Introduction to Automobile Engineering.

2. Chassis and Frame.

3. Suspension System.

4. Steering System.

5. Braking System.

6. Engine.

Day : 2


1. Steering Dynamics and Suspension Dynamics.

2. Braking Dynamics.

3. Aerodynamics of an Automobile.




Day : 3


1. Basics of Solid Works.

The basic feature like point, line, circle and selection of plane for a drawing

were taught under basics. The students were taught about the importance and

applications of 2D drawing and 3D modelling using solid works software.

2. Design of Rim of Tyres ( Steel and Alloy Rim)

The selection of tyres and design of rims based upon different parameters and

applications were taught under this topic.




Day : 4

Topics covered for the day 18-04-2015

1. Design of Steering System:

The steering system selection based upon the steering parameters and

requirements and the design of steering system were taught under this topic.

2. Design of Braking System:

The braking system design and the selection of brakes with respect to the

requirements like braking torque were taught under this topic.

The master cylinder selection is the critical parameter which is needed to be

selected based upon the disc brake.

Day : 5

Topics covered for the day: 19-04-2015

1. Design of Suspension system:

The suspension system design is the most important part of the vehicle design

since it absorbs the sudden impact loads when the vehicle travels through the

humps and bumps.

Double wishbone suspension was selected for this vehicle since it can

withstand any type of impact.

2. Design of Transmission System:

The transmission system transfers the power from the engine to the axles

which are the driven members of the vehicle.

The design of transmission system and the chain selection type was covered

under this topic.

Day : 6

Topics covered for the day : 20-04-2015

The Structural Analysis was performed on the chassis in SOLID WORKS.

The Dynamic Analysis was performed on the suspension system using Lotus

Suspension Software.




Day : 7

Components fabricated for the Day: Date: 21-04-2015

1. The students were divided into three teams (Each team containing 10 people).

The steel pipes required for fabricating the chassis were bent and sufficient numbers were

segregated and some pipes were welded




Day : 8


1. The bent steel pipes were welded together to form the chassis of the vehicle. It is done

according to the model created in Solid Works Software.

The steel pipes required were further cut from the raw materials and were segregated.

Day : 9


1. The required amount of sheet strips were cut from the Aluminium sheet roll and were

welded to the chassis for mounting the gear box.

2. The required number of bushes were identified for the tie rods of the double wishbone

suspension and tapping operation was performed on it for getting the internal thread.

3. The brake pedal and the clutch pedal were mounted on to the chassis.

4. The required amount of components were welded for the double wishbone

suspension.

5. The work for the day ended at 08:00 PM.




Day : 10


1. The brakes, suspensions, wheels and the shock absorbers were fitted to the chassis of

the vehicle.

2. The driver seat ergonomics were checked.

3. The vehicle body were fabricated and it will be welded to the chassis by 25-04-2015.

Day : 11


1. The brake discs were fitted to the rear part of the vehicle.

2. The steering system (Rack and Pinon) was fitted to the vehicle.

3. The gear box (Transmission system) was fitted to the vehicle.

4. Aluminium sheets (Outer body) were welded to the bottom portion of the chassis.

Day : 12


1. The Engine was mounted to the rear part of the vehicle above the gear box.

2. The fuel tank (300 ml) was fitted to the side portion of the chassis.

3. The control pedals (Accelerator, Brake and Clutch) were mounted to the front portion of

the chassis.

4. The hydraulic oil reservoir (for Disc brake) was fitted to the front portion of the vehicle.




5. The acceleration cabling was done at the end of the day.

6. The complete assembly of the vehicle will be done by 27-04-2015.

Day : 13


1. The fire shield was fitted to the rear part of the vehicle.

2. The driver seat was mounted to the vehicle. It is made of double layered Fibre

Reinforced Plastic (FRP).

3. The engine was fine-tuned and made ready for testing.

4. The gear lever was fitted to the left side of the driver seat and it was connected to the

gear box.

5. The vehicle was test driven at 04:00 PM.

6. The body panel works will be completed by 28-04-2015 evening and the vehicle will be

ready by the end of the day (28-04-2015).

Day : 14

Activity for the Day: Date : 28-04-2015

The aluminium body panels were bolted to the vehicle and the vehicle was ready to be

tested.

The vehicle was test driven by the end of the day.




Day : 15

INAUGURATION OF ALL TERRAIN VEHICLE: Date : 29-04-2015

The All-Terrain Vehicle was inaugurated formally by Fr. Antony Puthuserry on

29-04-2015 at 12:00 PM.

The vehicle is powered by 190 CC Briggs and Stratton Engine which gives a power of

6.5 bhp.

A total of 32 B.Tech (Mechanical Engineering) students were involved in building

this vehicle starting from scratch in association with the faculties from Elite Techno

Groups, Jaipur.

The vehicle building started with the design phase from 15-04-2015 to 20-04-2015.

The fabrication phase started from 21-04-2015 and it was completed on 28-04-2015.

The management, faculties involved (internal and external) and the students were

fascinated in making the All-Terrain Vehicle.

The students acquired more practical knowledge in making an All-Terrain Vehicle.

The event heads are Dr. Iven Jose (Associate Dean) and Dr. G.S.Hebbar (Coordinator,

Mechanical Engineering).

The faculty coordinators are Prof. N. Ram Kumar (Assistant Professor, Mechanical

Engineering) and Prof. S. Arun Raj (Assistant Professor, Mechanical Engineering).

A team of 25 students will be selected by the faculty (internal) from this internship

programme (based upon their performance in the internship) and those students will

be registering for the event SAE BAJA (A national event conducted by SAE (Society

of Automotive Engineers).

All-Terrain Vehicle (ATV)




Fr. Antony Puthuserry inaugurated the ATV by cutting the ribbon




Day : 16

Work done by the students: 30-04-2015

The students were divided into five different teams. They are

a. Braking System.

b. Steering system.

c. Transmission system.

d. Suspension System.

e. Chassis.

1. The students were briefed about the projects.

2. While testing the vehicle on 29-04-2015, the right rear wheel axle got cut and the

students were instructed to fix it before they start with the projects.

3. Students started to fix the right rear axle.

4. A team leader was appointed to each team and the students will be reporting their

progress to them and the leaders will be reporting to the faculty coordinator.

Day : 17


1. The students continued to fix the axle.

2. A 2 mm steel pipe is used as a coupling for connecting the axle to the connected to the

wheel.

3. The coupling was welded (both circumferentially and in longitudinal manner) to the

shafts on the either side.

4. A test run was again conducted on the vehicle.

Day : 18


1. The students started with the projects and each team showed a good progress.

2. The braking system and steering system team started to design the braking system and

25% of the brake system and steering system design was completed.

3. The chassis team has completed 15% of the chassis design.

4. The wheel and the gear train team completed 20% of their design.




Day : 19


1. The chassis team completed about 40% of the design.

2. The steering system, gear system, braking and suspension system team completed

about 35% of their systems design.

3. The vehicle was test driven by evening and a bend was found on the steering rack.

4. The students were involved in fixing the steering rack and it was fixed by the end of

the day.

Day : 20


1. The chassis and other teams completed about 50% of their design.

2. The faculty coordinator (Ram Kumar) advised the students to collect data regarding

the top ten teams who won prize in Baja 2015.

3. The students have to collect the specifications of the braking system, steering system,

wheels, suspension system, and Transmission system and out of which they will select

the best specification and they will using it for their All-Terrain Vehicle (A kind of

Reverse Engineering).

Day : 21


1. The chassis team completed about 75% of the design.

2. The braking system team designed the Master cylinder for the disc brake.

3. The reverse gear linkage design was completed by the transmission team.

4. The suspension system team completed 75% of the design.

Day : 22


1. The chassis team completed their design with side impact members fitted to the

chassis design.

2. The chassis team joined with the suspension team.

3. The braking team completed 75% of their work.

4. From 09-05-2015 the students will work on the projects (Practical Hands on session)

and they will be completing their projects on 14-05-2015.




Day : 23


1. The suspension team, braking team and transmission team completed 90% of the

assigned design work.

2. The steering team completed 85% of their design.

3. The students were advised by Prof. Arun Raj to procure the necessary spares for the

hands on project.

Day : 24


1. The suspension, braking, transmission and the steering team completed their design in

solid works.

2. The students collected the required the details of the top 10 teams who won prize in

Baja 2015.

Day : 25


1. The day begun with the testing of vehicle.

2. The steering team and along with other teams began with project of fixing the steering

stopper.

3. The steering stopper is fixed in order to ensure the safety of the steering rack.

Steering Stopper welded to the rack of the steering system




Day : 26


1. The students tested the vehicle to check the effectiveness of the steering stopper.

2. The transmission team along with the other teams started working on fitting the

reverse gear linkage.

3. The reverse gear linkage was fitted at the end if the day and the vehicle was tested.

4. A demo run was given to the CMI fathers (Principals of the CMI institutions all over

India) at 05:30 PM.

Students grinding the gear lever




Students fixing the reverse gear linkage

Prof. Ram Kumar explaining about the vehicle to CMI fathers




Day : 27


1. The braking team along with other teams started with fitting of the brake lights and

hydraulic switch to the vehicle.

2. The brake light will be powered by 12V battery.

3. LED light is fixed at the rear end of the vehicle.

4. Whenever the driver applies the brake the circuit is closed and the brake light gets

illuminated.

5. A test ride was conducted at the end of the day.




Day : 28


The engine was fitted with a new muffler to increase the performance of the vehicle

and to reduce the noise pollution.

The vehicle was test driven at the end of the day.

Day : 29


The vehicle was test driven and was checked for any leakage from any of the tanks

and sumps.

The leakage in the gear box was identified and it was fixed.

The vehicle was test driven at the end of the day.

Day : 30


The speed test, acceleration test and the braking tests were conducted on the vehicle.

The vehicle was test driven on various types of terrains present in our campus.

The vehicle was found to be stable when it moves even in the deep terrains.

Submitted by

N.RAM KUMAR.

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CHRIST UNIVERSITY FACULTY OF ENGINEERING, … Internship... · department of mechanical engineering...

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