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
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E (i
n M
eter
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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 !!!