SAEINDIA BAJA VIRTUAL 2018

TEAM

OLD TEAM ID -
17309 TEAM ID -19116

CAR NO. - 129

ENDURANCE SCORE - 0 Faculty Adviser: Team Captain:
TOTAL SCORE - 146.1 • Mr.RAHUL SHARMA •ANUJ JAIN
• Mr.RAHUL SAMRE
 LESSON LEARNT 2-A
SUBSYSTEM ISSUES IN 2017 ATV CORRECTION ADVANTAGES 2017
Nose of the roll cage increase Elimination of the nose Reduction in length .
Roll cage overall length .
Asymmetric roll cage about the Symmetric roll cage Symmetric subassemblies
central plane. about the central plane.
Power Train Larger gear ratio i.e. 12:1 Gear ratio taken 8:1 Higher acceleration .
Small track- width i.e. 50 Track-width is  Ensuring greater roll resistance
inches significantly increased  More stability
i.e. 52inches  Prevents plunging out of axle.
Small length of wishbone . Increase in length of  Controlled camber change rate
Suspension
wishbone.  Better wheel travel.
2019
High stiffness of spring- Fox 3Evol-R are selected Fox 3Evol-R featuring both high and
damper for rear-suspension. low speed compression damping as
well as rebound
Improper mounting of caliper  Fixed-type caliper Better clamping efficiency of break
on knuckle hindered floating  Integrated mounting pads
Brakes of calipers. on knuckle

Improper routing of lines. More flexible brake lines Uniform pressure transfer throughout
of required length the brakes lines.
More steering ratio 12:1 Reduction in ratio i.e. Effective turning.
Steering 6:1
Strong bump steer due to Minimum bump steer Minimum bump steer and less impact
improper alignment of tie-rod geometry on drivers hands.
 TECHNICAL SPECIFICATIONS COMPARISON 2-B
PARAMETER BAJA – 2017 BAJA - 2019 PARAMETER BAJA 2017 BAJA 2019
Vehicle Length 2032 mm 1766 mm Tube Dimension Primary : 1.25” x 2mm Primary:1.25” x 1.6 mm
Vehicle Width 1474 mm 1498 mm Secondary: 1” x 1.2 mm Secondary : 1” x 1.6 mm
Vehicle Height 1603 mm 1603 mm Roll Cage Material AISI 4130 AISI 4130
Overall
Dimensions Roll cage Mass 34 kg 28kg
Wheel base 1475 mm 1372 mm
Suspension Spring Shock up Fox Float 3 Evol R
Wheel track 1270 mm 1321mm
Front Suspension Double wishbone Double wishbone
Ground Clearance 380mm 380mm
Type
Wheels & Tyres Front & Rear 558.8mm 558.8mm (dia.) Rear Suspension Trailing Arm Trailing Arm
wheel size (dia.) Type
Maximum speed 57.70 km/hr 56.19 km/hr Gear Box 12:1 8:1

Overall Maximum 4.20 m/s2 5.7m/s2 2017 2019

Performance Of acceleration
Vehicle Stopping Distance 11900 mm 9290 mm
(at 55 km/hr)
Gradability % 46.48 71
Weight Kerb Weight 221kg 160kg
FAW:RAW 35:65 40:60
Steering Ratio 12:1 6:1
 ROLLCAGE DESGIN AND ERGONOMICS 3
ERGONOMICS SAFETY MAIN DIMENSIONS
2017 2019 Egress in less than 5sec 5 point Safety Harness 2017 2019
Sufficient Legroom
Fire Extinguisher within Length 1930 mm 1764 mm
Comfortable driver reach
position with sufficient
clearance Complete Driver’s Kit Width 800 mm 900mm

Unhindered Line of Sight

2 Kill switches Height 1212 mm 1212 mm
Sufficient Reach Envelope
Increased thickness of Foam Padding on roll
secondary member for cage members Kerb 221Kg 160kg
driver safety Weight

RULEBOOK REQ. OUR DESGIN

Primary member: Primary member:

MATERIAL AISI 1018 AISI 4130 1”OD*1.6mm 1.25”OD*1.6mm
Yield Strength 370 MPa 460MPa
Secondary member: Secondary member:
Tensile 440 MPa 560MPa
1”OD*0.83mm 1”OD*1.6mm
Elongation % 28.5% 24.5%
CHEMICAL COMPOSITION OF SELECTED MATERIAL (%)
Density 7.87 gm/cc 7.85 gm/cc
MATERIAL Cr Mn C Si Mo S P
Young's Modulus 205 MPa 205MPa
AISI 4130 1 0.60 0.33 0.3 0.25 0.040 0.03
Hardness (B) 126 197
 CAE METHODOLOGY 4
Modifications
Determining decision CAE of CAD CAE of modified
variables
Hand Sketching CAD Modelling based on CAE
Rollcage
Final Design
Model Results

BENDING BENDING
THICKNESS
MATERIAL OD (mm) STRENGTH STIFFNESS
(mm)
(Nm) (Nm2)
AISI 1018 25.4 3 387.38 2791.12
FRONT REAR
AISI 4130 31..8 1.6 500.22 3540.110
IMPACT FORCE CALCULATION ELEMENT SIZE: 5 mm
(SPEED LIMIT)
ELEMENT 2D
Front t=0.2 sec
TYPE:
Impact
SIDE ROLLOVER Side Impact t=0.3 sec TYPE OF Static
ANALYSIS:
Roll Over t=0.4 sec
TOTAL MAX. Rear t=0.2 sec
R MAX. CAE PROCESS TOOL USED
CASE APPLIED FOS DEFORMATION( Impact
e STRESS(MPa)
FORCE (N) mm) Creo
s Velocity 15.55m/s & 10m/s
uFront Impact 9000 4G 325.6 1.41 2.1 Parametric
Computer Aided
Formulae Work Done=Force*disp. 3.0,
lRear Impact 9000 4G 341 1.34 1.9 Designing
Used Work Done=0.5mv2 Soildwork
t F=0.5*mv2/d Voxelizer
Side Impact 6000 3G 355.1 1.29 5.5
s Disp.=speed*time
Front Roll Over 4500 2G 85.66 5.37 4.5 Analysis ANSYS 14.0
Hypermesh 13
 SUSPENSION DESIGN 5
SUSPENSION PARAMETERS Sprung & Sprung – 120 kg
unsprung
Suspension Front Double Wishbone Unsprung – 40
mass
Type kg
Rear Trailing Arm
DNF (Hz) Front-1.175Hz
CG Height 19 inch Rear-1.047Hz
Ground clearance 15 inch Ride rate Front-2.496
Linkage N/mm
design Roll centre height 14 inch
Rear-2.856 Deformation = Wishbone Stress=173 MPa
Motion Ratio 0.69 N/mm 0.456mm

Camber Front : -3 degree Suspension Front-152.4mm

Design travel
Rear-152.4mm
Rear : -2 degree
of Spring Front-16.7
Castor 4 degree spring stiffness N/mm
Suspension KPI 10 degree Rear-27.51
geometry N/mm
Toe in or toe out -1 degree [toe in]
Factor of safety= 2.5
Spring Force 1569.6 N Deformation =
Scrub Radius 27.6 mm
0.485mm
Trailing Arm Stress=163 MPa
Wheel Center Front :7.95
Rate (KW) N/mm
Rear:12.74
N/mm
Roll Rate (Kϕ) Front: 2177.5
N-m/rad
Rear:2465.48
N-m/rad Factor of safety= 2.6
 BRAKES 6
BRAKE CIRCUIT
CHOSEN CONFIGURATION: Brake Circuit
Type of split F/R Split Front and Rear- Disc Brake
• Reduced weight
Master cyl bore size x 19.05mm * 71.12mm • Better heat dissipation BRAKE DISC
stroke Installation problem-
Brake Disc  Bleeding-10% of fluid

Brake Calliper Cylinders- 25.4mm , N-2

bore size x no's
Calliper pad-mean r=82.3mm
braking radius, area, Area= 2857.42mm2
fraction coefficient Friction Coefficient=0.4

Brake fluid Dot 4 Temperature = 240.74 deg C Total Heat Flux = 4.0217*105 W/m2
BRAKE CALCULATIONS PERFORMANCE VELOCITY 40 45 55 56.19 60
Weight transfer at 40kmph to 0 kmph 345N km/h km/h km/h km/hr km/h
Deceleration 12.56m/s2
Static rolling radius for tyre 269.4 mm Stopping 4.91 6.22 9.29 9.69 11.05
Pedal Force & Pedal 265N &
Coefficient of friction for road 0.6 Travel 3.13’’ distance(m)

Brake torque required per wheel F- 484.41 N-m

FAILURE IN SYSTEM OLD NOW
R- 323.1 N-m
Fluid line Long and many turns Small length & straight
Force required by calliper cylinders 1722.5 N
Caliper mounting Improper mounting points. Proper mounting points.
Balance b/w two braking circuit Simultaneous
locking Effective disc radius 74mm 84.38mm
 STEERING 7
STEERING SPECIFICATIONS STEERING GEAR
STEERING SYSTEM Centralized steering system
86.47 Rack length(Eye to Eye) 14”(355.6mm)
Ackerman %
Turn lock to lock 2.8 turns
Ackerman Angle 21 deg
Steering ratio 6:1
Steering angle Inner angle : 44
Wheel track 52 inch
Outer angle: 29.24
Wheel base 54 inch
Under steer or Over steer Under steer
Length of tie rod 282.8 mm
Turning radius 84.9” (2156.6mm)
Rack travel (End to End) 4” (101.6mm)
Steering arm length 4” (101.6mm)
IBJ (From Central Axis) 7” (177.8mm)
STEERING COLUMN OBJ (From Central Axis) 18..135” (460.6mm)
Type Tilting type
Knuckle
With or without power assist Without power assist
Stress =207MPa Displacement=0.422mm

STEERING WHEEL
Steering wheel dia. 330 mm

Steering Effort 44 N

Steering wheel torque 6.76 Nm

 ENGINE AND TRANSMISSION 8
POWER FLOW Engine CVT Gearbox Drive shaft Wheels
PERFORMANCE GEARBOX COMPONENTS OVERALL REDUCTION ( CVT CV Tech + CUSTOM GEAR BOX)
Top Speed < 60 km/h
Drive Ratio Velocity Acceleration Gradebility Coupling
Grade Angle ≥ 35°
ENGINE Low Ratio 37.5 35.45
56.19 Direct
5.69m/s2 ղ= 71%
Engine Briggs & Stratton High Ratio 7.125 km/h Coupling
OHV 305 cc
Custom Gear Box Design & FAE Gear
Max Power 10HP@3800RPM
POWERTRAIN & INSTALLATION
Max Torque Parameter Description
TYRE SIZE 19.65N-
m@2800RPM Material A1 6061 T6
Front/Rear 22×7 /10
Density 2.7 g/cc
Casing
NVH
Yield
276 Mpa
Structured CAE Strength
Body Mounting Concepts Material EN 31
Density 7.8 g/cc
Power Train Mounting Strategy Gear PARAMETER VALUES
Yield
GEARBOX SPECIFICATION GEAR RATIOS 450 Mpa Module 2.5mm
Strength
Gearbox Constant mesh 1st Reduction 3.535 Oil Capacity 600ml Pressure Angle 20 degree
No. of reduction 2 SAE Profile Involute
2nd Reduction 3.535 Oil Grade
Gear Spur Gear 80W90 Stress 119.88 MPa
Overall 12.5
Viscosity Index 103 Deformation 0.08
Lubrication Splash Type Reduction
 WEIGHT AND COST COMPARISON 9
COST ANALYSIS BoM and Estimated Cost
COMPARISON B/W BAJA 2017 & BAJA 2019
System Estimated Cost Approx. Weight
2017 2019 2017 2019
1.Frame and Body Rs. 25000 Rs. 21300 32 kg 28 kg

2.Engine Rs. 73148 Rs. 65915 26 kg 27 kg

3.Transmission Rs. 100000 Rs. 52300 25 kg 19 kg

4.Brakes Rs. 15000 Rs. 15200 8 kg 6.1kg

5.Wheel Assembly Rs. 50000 Rs. 32000 45 kg 37.9 kg

WEIGHT ANALYSIS
6.Suspensions Rs. 35000 Rs. 224700 45 kg 15 kg

7.Steering Rs. 10000 Rs. 29750 12 kg 8 kg

8.Electricals Rs. 10000 Rs. 4000 5 kg 4 kg

9.Safety Equipments Rs. 30000 Rs. 63500 8 kg 5 kg

10.Miscellaneous Rs. 45000 Rs. 30000 15 kg 10 kg

Total Rs 393148 Rs 538665 221 kg 160kg

PROJECT PLAN 10
 DFMEA 11
COMPONENT FAILURE MODE FAILURE CAUSE FAILURE EFECT S O D RPN PREVENTIVE ACTIONS

TRANSMISSION Mechanical failure Fatigue/ cyclic Vehicle becomes 9 2 3 54 Choose transmission system according to
loading inoperable given load, performance and other
specification
FRAME Structural failure; Axial stress Overall Damage to roll 9 1 1 9 Choose material with appropriate/high
Bending and breaking exceeds yield cage. Frame breaks or factor of safety(FOS), effective design and
of frame stress of material bends. Driver’s safety is analysis; constant testing.
due to excess load endangered
and impact
loading.
RACK AND Mechanical failure, Obstruction in Steering failure; Safety 6 2 1 12 Verification of desired specification and
PINION Leaking of fluid, movement of of driver and others testing
Loosening of Lug nut pinion over rack, compromised
damage to
components

A-ARMS AND Bending, Breakage, Axial stress Damage to suspension 7 2 1 14 Choose material with high FOS and
TRAILING ARM cracks structural exceeds yielding system and rough according to vehicle specifications;
damage and stress of material operation or non- effective design and analysis
mechanical failure. due to excess load operation of the vehicle
and impact loading
 PFMEA & DVP 12
S. No Description Acceptance Criteria Test Method Assigned to
1. Tensile Strength Of Pipe Application Based Tensile Strength Test on UTM Validation Head
Bending Strength Test
2. Weld Strength Test Weld should not crack or break Validation Head
& Tensile Strength Test using UTM
3. Shear Strength of Brackets Application Based Shear Strength Test on UTM Validation Head
Not less than 75% energy should be
3. Engine Mount Durability Vibration test using accelerometer Transmission Head
absorbed by mounts
4. Alignment of Pipes No variation of calibrated spirit level Using gyroscopic device Validation Head
Determination of coefficient of stiffness
5. As designed Load Test Suspension Head
of spring
6. Brake circuit No leakages Visual inspection Validation Team
7. Kill switches Should work properly Multi-meter and test circuits Electrical Team
Using Resistance Temperature
8. Temperature of Firewall Should not exceed 40 C Validation Team
Detector
Process Failure Modes Effects of Failure Cause of Failure Current Controls O S D RPN
Function
Welding Discontinuous, Failure of different mount Improper handling of Practicing good welding 2 8 1 16
undercutting & roll cage members electrode gun techniques

Pipe cutting Inaccurate Inefficiency of stability of Human error, improper Proper marking before 1 9 1 9
dimensions vehicle handling of cutter cutting
Grinding Sharp edges, Can cause injuries Ignoring sharp edges Proper grinding all sharp 1 8 1 8
unfinished surface edges
 Team Captain
Anuj Jain
13
Faculty Advisor - Mr. Rahul Sharma
Mr. Rahul Samre
Team Vice-Captain
Jasmeet Singh

Steering Suspension Eng. And Trans. Brakes & tyres Rollcage Analysis Marketing
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• Mansi • Devendra • Ratnakar • Rahul • Aayam • Jasmeet • Ratnakar
• Gourav • Mayur • Mohak • Kaushal • Yash • Akshat • Jasmeet
• Nitin • Sangam • Manish • Akshat • Bobby • Himanshu
College Facilities-
Facilities Not available in
available in college
college
Drilling Machine Material
Testing(Spectrometer)
CNC Lathe
LATHE CNC LATHE UTM Welding Machine Bending Machine
Strength -
Testing(UTM)
3D Printer
Lathe Machine -

MIG DRILLING 3D PRINTER Thank You..