ITM University,Gurgaon

Outline of presentation

1. RULEBOOK AND IT’s CONFIRMANCE2. COLLEGE FACILITIES3. TEAM DETAILS4. DESIGN VALIDATION• FRAME DESIGN AND ANALYSIS• SUSPENSION VALIDATION• STEERING VALIDATION• BRAKE VALIDATION5. AIRFOIL AND NOSE DESIGN ANALYSIS 6. 3-D MODELLING7. DRAFT TECHNICAL SPECIFICATIONS8. INNOVATION9. PROJECT PLAN10. COST REPORT 11.TEAM SPONSORS

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RULE BOOK CONFIRMANCE 3

SUSPENSION

Wheel travel of at least 50.8 mm , with driver seated. Wheel travel is taken as 79 mm with driver seated.

Minimum static ground clearance = 25.4 mm Ground clearance under static load = 63.5 mm

FRAME AND WHEELS

Front and Main Roll Hoops =38 x 2.4 mm, 40 x 2 mm 40 x 2 mm

Side Impact Structure, Front Bulkhead, 25.4 x 1.65 mm 25.4 x 2.5 mm

Front Bulkhead Support , 25 x 1.5 mm 25.4 x 2 mm

Shoulder Harness Mounting , 25 x 2.5 mm 25 x 2.5 mm

Front bulkhead support, side impact bracing, 25.4 x 1.5mm

25.4 x 1.5 mm

Roll Hoop Bracing, 25.0 mm x 1.75 mm 25.4 x 2 mm

The material for the primary structure have to be Round, mild or alloy, steel tubing (minimum 0.1% carbon)

Alloy steel AISI 4130 with carbon content0.28-0.33

Wheelbase of at least 1524 mm (60 inches). Wheelbase of the vehicle-1778mm(70inches)

The smaller track of the vehicle (front or rear) <= 75% of the larger track.

The smaller track width is1295 mm and larger is 1320.8mm, which is 98% of the larger track.

The wheel size must be 8 inches or more in diameter 145/70 R-12

STEERING

The steering wheel must be mechanically connected to the front wheels

M800 Rack and Pinion

BRAKES

Brake system must act on all four wheels & controlled by single pedal.

The car is equipped with diagonal hydraulic linkage , The brakes used will be disc brakes on all four tires of 9.3inches diameter.

ENGINE AND TRANSMISSION

Engine used is M-800 BS-3 MPI Engine with Transmission .

Engine used is M-800 BS-3 MPI Engine(sponsored) Transmission is inclusive with the engine. 4 forward +1 reverse manual gearbox

AIRFOIL

All wing leading edges must have a minimum radius 12.7 mm (0.5 inch)

The airfoil we have designed have radius of 12.7 mm (0.5 inch)

In plan view, no part of any aerodynamic device, wing, under tray or splitter can be further forward than 460 mm (18 inches) forward of the fronts of the front tires

In plan view, the airfoil is 430 mm forward of the front the tires.

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Engine (Cross Section)

Bench Drill Universal Testing Machine MIG Welding

Engine Testing

Facilities available in our College

Power Hacksaw

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Lathe M/C CNC Machine

Milling M/C

Power Mill

Shaper

Hi-tech CAD labs

Hand Grinder

Forging Bench

TEAM DETAILS 6

S.No NAME SAE No. DEPARTMENT1 JATIN GOEL 7110323493 DESIGN ( TEAM CAPTAIN )2 PRABHAT TIWARI 7110323473 DESIGN3 GAURAV SAINI 7110323336 BRAKES+TYRES+WHEELS4 KARAN MAHAJAN 7110323498 BRAKES+TYRES+WHEELS5 SUMIT CHOPRA 7110323487 BRAKES+TYRES+WHEELS6 HIMANSHU GUGNANI 7110323345 BRAKES+TYRES+WHEELS7 GAUTAM CHABRA 7110323340 STEERING+SUSPENSION8 LAKSHAY GANDHI 7110323357 STEERING+SUSPENSION9 KARTIK KHURANA 7110323500 STEERING+SUSPENSION10 YOGANSHU KAKKAR 7110323458 STEERING+SUSPENSION11 NITIN RANA 7110323471 POWERTRAIN12 ABHISHRESHTH DESWAL 7110323491 POWERTRAIN13 AKSHAY VASHISHTA 7110323496 POWERTRAIN14 KANCHAN VASHISHT 7110323480 FABRICATION15 SANCHIT TONDAN 7110323405 FABRICATION16 ISHU JAIN 7110323410 FABRICATION17 ANKIT DHIMAN 7110323313 FABRICATION18 SWATI MEHNDIRATTA 7010310708 FABRICATION19 KARAN BHARDWAJ 7110323499 FABRICATION20 ABBHIYANK GOVIL 7110323302 COST+PROCUREMENT21 DHRUVAY JAIN 7110323501 COST+PROCUREMENT22 SIDHARTHA JAITLY 7110323423 ELECTRICALS23 LOKESH MITTAL 7110323472 MARKETING24 MOHIT GREWAL 7110323363 MARKETING25 VIKAS SHARMA 7110323451 MARKETING26 VINKEL ARORA 7110310057 FACULTY ADVISOR

Views of FrameFRONT VIEW

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SIDE VIEWTOP VIEWISOMETRIC VIEW

DESIGN VALIDATION

FRAME material

MATERIAL AISI 4130

C% 0.28-0.33

Mn% 0.4-0.6

Si% 0.15-0.35

S% 0.04 Max

Mo% 0.15-0.25

Mn% 0.60-0.90

Fe% 97.3-98.2

P% 0.035 Max

Yield Stress 435 MPa

Tensile Strength 670MPa

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SOFTWARE used: SOLIDWORKS and ANSYS 12.

Material: ALLOY STEEL (AISI 4130).

FRAME DESIGN ANALYSIS

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The following tests were done on the frame:

• FRONT IMPACT • REAR IMPACT• ROLL OVER IMPACT• SIDE IMPACT

FRONT IMPACT :

In Front impact test, it is assumed that two bodies moving in opposite direction collide head on.

Force of Impact = 26249.4N Max. Stress Induced = 224 MPaMax. Displacement = 1.5 mm

REAR IMPACTIn this type of impact, a body will hit to the frame of the vehicle on its rear. The force encountered will be:Impact Force = 13122 N

Max. Stress Induced = 224.2 MPaMax. Displacement = 3.21 mm

ROLLOVER IMPACTThe force used for roll over analysis is dependent on the weight of the vehicle and center of gravity locationIn analysis we consider 3g effect :Force calculated on front hoop = 8343 NForce calculated on main hoop = 13230 N

Max. Stress Induced = 353.4 MPaMax. Displacement = 5.37 mm

SIDE IMPACTIn this type of impact, a body will hit to the frame of the vehicle on its side. The force encountered will be:Impact Force = 13122 N

Max. Stress Induced = 252.1 MPaMax. Displacement = 2.53mm

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SUSPENSION VALIDATIONValidation of Spring Design by IST Spring Design Software

Kinematic Model

STATIC CAMBER -1.0˚

CAMBER GAIN IN JOUNCE -0.81˚/1"

CAMBER GAIN IN REBOUND 0.62˚/1"

CASTER 5˚

KINGPIN INCLINATION 3˚

SCRUB RADIUS 1.02"

TOE IN 0˚

GROUND CLEARANCE 3"

STATIC ROLL CENTER 2.5"

FRONT TRACK WIDTH 52"

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STATIC CAMBER -1.0˚

CAMBER GAIN IN JOUNCE -0.06˚/1"

CAMBER GAIN IN REBOUND 0.34˚/1"

CASTER 5˚

KINGPIN INCLINATION 1˚

SCRUB RADIUS 1.332"

TOE IN 1˚

GROUND CLEARANCE 5"

STATIC ROLL CENTER 3.5"

FRONT TRACK WIDTH 52"

Front Suspension GeometryRear Suspension Geometry

KINEMATIC MODEL

KINEMATIC MODEL

Front Suspension

ANTI DIVE

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The geometry is designed so the front control arms absorb approximately 40% of the longitudinal force due to braking. This is to keep the suspension from bottoming out when braking and possibly hitting a bump at the same time

ANTI SQUAT

The geometry is designed so the rear control arms absorb approximately 40% of the longitudinal force due to acceleration. This is to keep the suspension to travel in condition of bump during acceleration.

STEERING VALIDATION

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Kinematic ModelDue to the light weight, low cost and simplicity of Rack & Pinion, we will use Maruti-800 Rack and Pinion

Specifications of Steering

No. of teeth on pinion = 6No. of teeth on rack = 24Rack length = 137mmRack Gain = 34.1504mmPlacement of steering ahead of axle = 3 inchesSteering ratio = 8.2

BRAKE VALIDATION

Rotor, outer radii 118mm

Inner radii 83mm

Placement outboard

Caliper 2 pistons

Bore Diameter of Piston

20mm

Here, friction radius

101.51mm

PART STATIC LOAD

Front Axle 180kg

Rear Axle 270kg

PART DYNAMIC LOAD

Front axle 249 kg

Rear Axle 201 kg

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Braking system has Disc Brakes at both Front and Rear wheels

UNDER STATIC CONDITIONS

UNDER DYNAMIC CONDITIONS

Brake torque requirement For front tires = 496.46 J For rear tires = 400.56 J

Braking Torque developedTorque developed at front = 768.3 JTorque developed at rear = 533.2 J

Braking torque developed by the brakes is more than the required therefore this results in locking of all wheels

AIRFOIL DESIGN AND ANALYSIS 16

Chord length = 317.5 mmLength of airfoil = 1320.8mmDistance of airfoil from ground = 63.5mmCoefficient of Lift, Cf = -1.024Coefficient of Drag, Cd = 0.0213Downforce = 182.56N

h/c ratio Coefficient of lift Coefficient of drag

0.075 -0.48 0.018

0.15 -0.52 0.012

0.2 -0.46 0.0090

0.35 -0.32 0.0067

0.5 -0.25 0.0055

RESULTS

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ANGLE OFATTACK

3 7 9 10 11 12 13 14

AIRVELOCITY

(m/s)29.16 29.16 29.16 29.16 29.16 29.16 29.16 29.16

LIFTCOEFFICIENT -0.299 -0.61 -0.852 -0.858 -0.866 -0.886 -1.024 -1.082

COEFFICIENT OF

DRAG.00034 .00676 .00784 0.0112 0.014 0.0145 0.0213 0.0292

COMPUTATIONAL FLUID DYANMICS OF NOSE

Coefficient of drag = 0.117Coefficient of lift = -0.12

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193D Modelling

20Detailed View

DRAFT TECHNICAL SPECIFICATIONS

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INNOVATIONS 22

•Enhanced Acceleration & Signaling

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 SPECIFICATIONSWheel Track(mm)FrontRearWheel Base(mm)Overall Length(mm)Weight of Vehicle(kg)Weight DistributionRatio(front:rear)

1320.81295.417782372450

40:60

SUB-SYSTEM SPECIFICATIONS

Engine & TransmissionCompanyTypeDisplacement(cc)Compression RatioTorquePowerTransmission

Maruti Suzuki India Ltd.Gasoline(Naturally Aspirated)7968.6:1 to 9:159 N-m at 2500 RPM26 KW at 5000 RPM4 forward + 1 reverse manual gearbox

Brake System

Front(Diameter,mm) Rear(Diameter,mm) No. of pistons Bore diameter of Piston(mm) Friction Radius(mm)

Disc brakes on all four wheels with separate hydraulic system for front and rear brakes.118118220101.51

Steering System Maruti 800 Rack and Pinion

Suspension Front Rear

Push rod , unequal wishbone

Double Wishbone with Helical Coil Spring

Tyres Front & Rear 145/70 R-12

PROJECT PLAN 24

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COST REPORT

TEAM SPONSORS2626