ROA ROADIES DIES Regd. ID : 81341 National Institute of Foundry - - PowerPoint PPT Presentation

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ROA ROADIES DIES

National Institute of Foundry & Forge Technology , Ranchi

Design Presentation

• Regd. ID : 81341

TEAM CAPTAIN TEAM VICE-CAPTAIN

TECHNICAL Design & Analysis Roll Cage Steering Suspensions Tires & Brakes Fabrication MANAGEMENT Publicity Sponsorship Procurement RICHARD DOLEY

AKSHAY TRIPATHI

VIKAS UTSAV

• KR. SAMBHAV

UTSAV MAHTO ANUROOP, RAJA,SATISH DHARMENDRA RAJAT

BITTU GUPTA ROHIT UJJIR MANAS GOND HITESH GODWANI

CHAITANYA DWIVEDI VISHAL PANDEY ABHIMANYU RAJ VARDHAN ANKIT GUPTA ASHUTOSH RISHIKANT

TEAM ORGANIZATION

ROLL CAGE

Material Carbon Steel AISI 1018 UTS 365 Mpa Carbon content 0.18% Outside dia.: Wall thickness: 25.4 mm 3.05 mm

DESIGN METHODOLOGY WELD JOINTS

• Driver-oriented Cockpit design.
• Light weight, Compact and simple.
• High Roll stiffness and structural rigidity
• Easy egress during mishap.
• Least no. of welds and members
• Number of weld joints
• Weld length

= 62 = 4.787 m

Roll Cage Analysis (Software: ANSYS 13.0)

Front Impact Analysis

• At Speed

: 60 km/hr (16.67 m/s)

• Impact Time

: 0.1 sec

• Thus, Load= 60000 N on front members.
• Max STRESS :

174 Mpa

• Max DISPLACEMENT : 2.38 mm
• Factor of Safety: UTS/Smax = 365/174

= 2.1

Side Impact (Safe case of Side Roll over)

• Load: 2G loading (6180 N) on side members.
• Max STRESS

: 69.4 Mpa

• Max DISPLACEMENT : 2.26 mm
• Factor of Safety : 365/69.4

= 5.25

Roll Over (Dynamic) Analysis

• Load: 2G Horizontal on side members

1G Vertical on top members.

• Max STRESS

:136 Mpa

• Max DISPLACEMENT : 5.5 mm
• Factor of Safety : 2.68

Suspension: Double Wishbone Parallel SLA

Upper arm 312 mm Lower arm 338 mm Upper arm 263 mm Lower arm 287 mm

Front

Lower arm , centre

Rear

Upper arm, inner

SHOCK MOUNTING LOCATION: LENGTH OF A ARMS: Front Rear REAR UPPER ARM FRONT LOWER ARM Front

81.66 mm

Rear

114.82 mm ROLL CENTER HEIGHT:

Steering

Gear Ratio 12:1 Caster 5° Positive Camber (static) 2° Negative Toe-in 10 mm King-pin Inclination 12° Scrub Radius 44 mm Lock Angle 40° (approximately)

• No. of turns to steer from Extreme Left

to Extreme Right 2.66 turns Turning Radius

Target Specifications:

• Rack and Pinion; simple design and easy to install.
• 100% Ackermann geometry

Braking System

Pedal Ratio 6.2:1 Braking Effort 1300 N per wheel Deceleration 7.53 m/s2 Stopping distance 21.5m (max speed 60 km/h) Assumption: Brake Efficiency = 70% Coefficient of friction =0.65 Formula used ῖ = BfwR/r Bf = Mag s = v2/ 2gaₓ/g

Maruti 800 calipers and disc will be used Target Specs: Features:

Hydraulic disc brakes Two independent braking circuit Equipped with SMART Turning Assistance System Two servo motor assisted valves on rear circuit. While turning left, on application of brakes will lock both the front wheels and rear left wheel. Rear right wheel with drive will get moment along these 3 locked wheel hence turning would be easier.

Power Train

Torque* (ft-lbs, gross) 14.50 Engine Displacement (cc) 305 Number of Cylinders Single Engine Configuration Horizontal Shaft Engine Technology OHV Length (in) 12.3 Width (in) 15.4 Height (in) 16.4 Weight (lbs) 50.4 Bore (in) 3.12 Stroke (in) 2.44 Engine Fuel Gasoline

SPARK PLUG RC12YC

Briggs and Stratton Engine: 10 hp OHV Intake 20S332 0036 New engine with 3800rpm Overhead Valve Design (OHV) Runs cooler and cleaner delivering more power, longer engine life and improved fuel economy

Flange Coupling

Safety & Ergonomics

Kill switches will be installed to kill the ignition in case of emergency All rotating parts will be properly shielded with sheet

• metal. Splash shields and Drip

pans will also be provided 5 point harness seat belt system along with neck restraint and arm restraint Belly pan running entire length of cockpit, Roll cage foam padding and body panels will be provided Fire extinguisher within the reach of driver will be provided SAE grade brake lights will be installed and all wiring will be properly insulated and clipped. Pivoted bumper with spring support in front

• f vehicle to absorb energy

from collisions Racing type 3 ways Adjustable seats, for driver comfort. Belly pan and Roll cage padding Gear indicator to enable quick gear shifts

Design Specifications

Overall length 2.3 m Track width Front: 1.55 m Rear: 1.45 m Wheel base 1.60 m Overall weight 310 Kgs (inclusive of Driver) Engine Briggs and Stratton 10hp OHV Transmission Mahindra Alfa(modified) Tires Rims 22 x 8 inches, 6 ply ATV 10 x 6 inches Roll Cage SAE 1018 seamless steel tubes 1” OD and 3 mm wall thickness Suspension (front and rear) Double Wishbone suspension (Parallel and unequal arms) Steering System Customized Centered Rack and Pinion Gear Ratio = 12:1 Braking (front and rear) Hydraulic Disc brakes Maximum Torque 19 Nm @ 2900 rpm Maximum Speed 60 KMPH

2-D views

Final View

Design Validation Plan

No Description Accomplishment Targets Allotted Resource Means Of Accomplishment

1.

Welding test

Strength of welded components should be within permissible limits. Abhimanyu Yadav

Universal Testing machine

2.

Ground Clearance Test

Should not be less than the specified value i.e. 10 inch Ashutosh Saraswat

10 inch Spacer.

3.

Braking Test

The vehicle should stop within safe limits and all the wheels should be locked Ankit Gupta

To be tested on track with 2 different observers for wheels on each side. Braking distance to be measured from point of brake application to point of stop.

4

Wheel Travel

Should be at least 6-7 inches (jounce rebound) Raja Sah

Ruler

5.

Straight Line Stability

Should move in a straight line when steering is at neutral position. Rohit Ujjir

Driving the car in neutral steering position parallel to the white strips on road.

6.

Turning Radius

Should be approximately equal to the calculated value. Anuroop Kulshresta

Radius will be measured using measuring tape.

7.

Fuel Leak Test

Should not leak fuel or fluid at any circumstances. Vishal Pandey

Vehicle should be tested in various roads conditions and any case of spills to be scrutinsed.

8.

Speed and acceleration test

By recording the time travel while traversing a path Hitesh Godwani

Obtained data shall confirm the calculated value

College & External Facilities

MACHINING Center Lathe Universal Milling Machine Grinding Machine Drilling Machine WELDING Metal Inert Gas welding machine TIG welding machine Electric arc welding machine MANUFACTURING MACHINES CNC Milling Machine Hot Isostatic Press(HIP) Machine Rapid Prototyping Machine TESTING MACHINES Brinell Hardness testing machine(3000 kg) Universal tensile testing machine(60 tonne) EXTERNAL FACILITIES: CNC Pipe Bending. Laser Cutting (for hubs). Paint Equipment.

Project Plan

Cost Estimates

Category Items Cost Frame

Steel tubes, Sheet Metal, Welding supplies, roll cage padding etc

37,200 Power Train

Engine, transmission, shifters, chains, sprocket, couplings etc

47,000 Wheels and tires

Rims & tires(4+2)

39,900 Suspension

Shocks, springs, A arms, uprights, hubs, spindles

22,000 Steering

Rack & pinion, steering column, steering arm, steering wheel, tie rods etc

11,600 Safety equipments

Driver’s suit, helmet, fire extinguisher, harness system, restraints, kill switch etc

37,500 Braking

Calipers, master cylinders, servo motors, brake lines etc

14,500 Misc

Travel, transportation, accommodation etc

30,000 Total 2,39,700

THANK YOU!!!