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Presentation on theme: "BHARATIYA VIDYA BHAVAN’S"— Presentation transcript:

SARDAR PATEL COLLEGE OF ENGINEERING SPCE RACING Reg. ID: 30469 Team Members Sameer Kolte (C) Parshva Shah Amol Alsundkar Chaitanya Joshi Prashant Ramteke Tushar Karande Shweta Patil Gaurav Munot Pratik Baldota Jaykishan Choksi Akshay Jain Priyank Gajiwala Aniket Ghatvisave Dhruv Phadke Omkar Deshpande Mukund Lahoti Sanskar Panse Nikhil Kotasthane Sagar Dalvi Siddhant Shah Sumant Kherudkar Presented By Sameer Kolte, Aniket Ghatvisave, Pratik Baldota, Parshva Shah, Priyank Gajiwala

2 Project Plan

3 Roll cage Design: Material and Cross Section Selection
Material Used: AISI 1018 Structural Steel Property Value Ultimate Tensile Strength 460 MPa Yield Strength 365 MPa Density 7850 kg/m3 Young’s Modulus 2 x e11 N/m2 Poisson’s Ratio Cross Section Moment of Inertia (mm4) Distance of extreme fibre (mm) Section Modulus (mm3) Area (mm2) Circular OD 1” 3mm Thick 12771 12.5 1022 207 OD 1.25” 2mm thick 20774 15.875 1308.5 187 Bracing: Circular cross section, OD =1”, pipe thickness= 2mm

4 Roll cage Design: Design Methodology
Objective: To provide minimal 3-D space surrounding the driver and ensure safety. Driver’s measurements: RRH design:

5 Roll cage Design: Design Methodology
RHO, SIM, FBM design :

6 Roll cage Design: Finite Element Analysis
Torsional Rigidity Torsional rigidity: 2500Nm/deg Stress Induced: 288MPa Flexural Rigidity Stress Induced: 107 MPa

7 Roll cage Design: Finite Element Analysis
Front Impact Rear Impact Rear Impact Force=5G=17167N Stress Induced= 123MPa Front Impact: Force=7G=24034N Stress Induced= 319MPa Side Impact Side Impact Force=3G=10300N Stress Induced= 334MPa

8 Roll cage Design: Human Ergonomics
Side Impact Member Height: 9”; Kept close to minimum for less driver exit time. Steering Wheel Position: Fixed according to driver comfort. Driver Head Clearance: 7.5”; Kept greater than 6” as specified in rulebook. RRH Inclination: 8 deg, fixed according to driver back leaning. Width of chassis: Fixed such that there is clearance of 3” between any chassis member and driver body part.

9 Suspension, Steering and Brakes: Chosen Configuration
Type: Hydraulic disc brakes Honda Aviator disc Pulsar 220 calipers Maruti 800 Master cylinder Suspension: Type: Double Wishbone unequal arm suspension (Front ) Double Wishbone, Twin outer ball joint suspension (Rear) Coil Spring and Hydraulic damping Steering: Type: Ackerman Steering Maruti 800 rack and pinion assembly

10 Brake System Human Foot force = 40kgf+ 20kgf(emergency)
Pedal Ratio = 4 Use of proportionate valve to achieve front: rear brake biasing. Calculated stopping distance: 3.6metres

11 Suspension Design: Kinematics
Bump/Rebound travel: Front 200/-100, rear 200/-80 (mm) ; Roll angle: 5 degrees Camber variation: Front: 0.85 deg/inch bump, 0.6 deg/deg roll Rear: 1.34 deg/inch bump, 0.42 deg/deg roll Static Data Front Rear Camber angle 0 deg Caster angle 7 deg Toe angle Kingpin angle 8 deg 6 deg Scrub Radius 90mm 120mm Caster Trail 23mm 0 mm Roll centre height 400mm 396mm Toe Variation: ZERO bump steer and Roll steer

12 Suspension design: Spring selection
Objective: To achieve desired ground clearance of 12” To achieve ‘oversteer’ while cornering. Spring selection: Rear springs: Maruti Zen Front struts Measured spring stiffness ‘k’ = 21N/mm Precompressive force= 140kgf Front Springs: Inhouse designed springs Target spring stiffness ‘k’ = 21N/mm

13 Wheel assembly components
Hubs: Front hub: Designed hubs Torsion and Bending Braking Torque= 235Nm Bending force= 1800N Max Induced stress= 71MPa Factor of safety= 6.5 Rear hub: Maruti 800 front hubs

14 Steering sub system Ackerman geometry C-factor = 37 mm/rev
Rack travel = 45mm Wheel angles: Inner= 43deg, Outer= 35deg Minimum Turning radius= 4 metres

15 Maximum stress induced= 23 Mpa
Powertrain: Engine Specifications: Briggs and stratton 10bhp OHV engine Torque: approx 18.75Nm at 2600 rpm Power: 10bhp at 3600 rpm Engine mounts: Operating frequency range: 25 Hz to 70 Hz Engine Mounts Natural frequency= 460Hz Maximum stress induced= 23 Mpa

16 Powertrain: Transmission
Schematic: Engine-> CVT-> Reduction gearbox Continuously Variable Transmission 1. CVTech CVT Ratio= 3.6:1 to 0.59:1 2. Comet 780 series= 3.75:1 to 0.6:1 Reduction gearbox Constant reduction = 10:1 Final ratio= 36:1 to 5.9:1

17 Powertrain: Reduction
Differential Input from CVT Output to driveshafts Total reduction: 11.45

18 Design Failure Modes And Effects Analysis (DFMEA)
Items Potential Failure Mode Potential Cause of Failure Potential Effect Of Failure Remedies to avert Failure Chassis Structural Front/Rear/Side Collision Driver Injury, Chassis deformation, Damage to engine/suspension. Incorporate bracing members, Nodal Structure, Use of Bumpers. Fatigue Resonance of engine frequency with chassis natural frequency. Failure of welded joints Use of rubber pad below engine, Incorporate bracing to increase natural frequency Suspension (A-Arms, Springs, Shock absorbers) Bending, compression, Force due to anti dive; Torsional shear failure of spring, Buckling Permanent buckling of spring affects ground clearance; Wishbone failure Rear twin Ball joint suspension , High Factor of safety Transmission Mechanical Cyclic loading, Radial loads due to CVT, Torsional shear stress in shafts Gear failure, Shaft failure, Misalignment of shafts in gearbox Use of standard shafts and gears, Bearings capable of taking high radial loads Brakes Brake fluid contamination, Bending of brake pedal, Bending of master cylinder rod Brake system failure Master cylinder cap, Brake Bleeding, High FOS for pedal, proper Master cylinder mounting

19 Safety Summary 5 point harness.
Battery placement: Away from rotating parts, Covered to prevent fuel spill on battery. Front and rear bumpers to protect tie rod and toe link. Master cylinder mount at height from base of chassis to prevent brake failure. Resilient foam material on all pipes of cockpit. Use of fire extinguisher. Summary Data Value Overall Length 90 inches Overall height 58 inches Track Width Front: 52 inches Rear : 50 inches Wheelbase 66 inches Gear Ratio 36:1 to 5.9:1 Estimated Weight of vehicle Gross Weight : 350 kg Kerb Weight : 290kg Estimated Weight of chassis 55 kg with all mounts and welds

20 3-D view of car


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