DESIGN 1

PRESENTATION
VIRTUAL BAJA SAEINDIA 2015

TEAM NAME : INFERNOS

TEAM ID : 16239
SAVEETHA ENGINEERING COLLEGE
Thandalam , chennai-602105
 SPECIFICATIONS 2
Overall vehicle Suspensi Front Rear
details on
Wheel base 63 inch Type Double Macpherso
Overall width 56 inch wishbone n strut
Overall length 86.44 inch Brakes Front Rear
Front track width 46 inch
Rear track width 52 inch Brake Type Disc Disc
Ground 10 inch
clearance Rotor dia 234.95 234.95
Engine/ BRIGGS AND
mm mm
Transmission STRATTON
Displacement 305 cc 3-D VIEW
Max. torque 18.5 Nm @2800
rpm
Max. power 7.45 Kw @
3800rpm
Type CVT
Make (oem) Polaris P90
Gear box Automatically
shifted gear box.
 ROLL CAGE 3
Material : All the members of the roll cage are made of AISI 1018 steel.
With an OD of 25.4 mm and a wall thickness of 3 mm. The structure of
these members is tubular in section.
PROPERTIES OF ROLL CAGE MATERIAL :
Material - AISI 1018
Yield Strength - 365 MPa
Ultimate Strength - 440MPa
Carbon composition - 0.18 - 0.20%
The total weight of the roll cage is estimated to be 66kg.
DRIVER ERGONOMICS :
Drivers Elbows to Side Impact Members : 6
Drivers Seat to Firewall (RRH) : 8
Drivers shoulders to SIM : 8
Helmet of the driver to top of the vehicle : 8
Helmet to The forward ends of the RHO members (LC) : 16
ROLL CAGE SPECIFICATION :
Overall Length : 86.44
Overall Width : 35
Overall Height : 48
Ground clearance : 10
 CAE Process and Analysis 4
FRONT REAR IMAPCT
IMPACT

Software : ANSYS R 15.0

Type : Static structural
Meshing size : Smart Mesh
Method
Maximum deformation : 0.028 used : Beam Method
Maximum deformation : 0.135
Factor of safety : 1.82 Factor of safety : 1.12
Material selected : AISI 1018
SIDE IMPACT ROLL OVER
Yield strength : 365 MPa
Tensile strength : 440 MPa
Elongation % : 15.0 %
MAX. LOAD APPLIED : 12000 N

Maximum deformation : 0.020 Maximum deformation : 0.028

Factor of safety : 2.02 Factor of safety : 1.82
 SUSPENSIONS
REAR
5
FRONT
PARAMETERS SUSPENSIO
SUSPENSION
N
Unequal,
McPherson
Type parallel, double
Suspension
wishbone
Wire diameter 10 mm 12 mm
Mean coil
63 mm 120 mm Toe
diameter
Number of
10 11
coils
Total length 379.73 mm 540.44 mm
Suspension
100 mm 100 mm
travel
Spring rate 13.8 N/mm 11 N/mm
Best suited Alto
Honda unicorn
OEM suspension
Lower
wishbone 9 inch 12 inch
length
Upper
wishbone 8 inch nil
length
Angle of upper
wishbone with
24.62 deg nil
respect to
ground camber
 BRAKES 6
1. BRAKING EFFORT(Driver on Pedal) : 25 kg / 245.25N
2. TARGET STOPPING DISTANCE : 10m
3. TARGET BRAKING FORCE : 4170 N

PARAMETERS ALTO SANTRO

Pedal Ratio 4:1 4:1

Diameter of master 0.875
0.75 inch
cylinder inch
Rotor effective 9.09 9.25
diameter inches inches
10.532
Stopping Distance 10.243 m
m

OEM SELECTED : HYUNDAI SANTROS BRAKING

SYSTEM
Weight transfer from 40 Kmph 0 Kmph : 317.93 N
Dynamic load acting on the front during braking : 1495.13 N
Dynamic load acting on the rear during braking : 2073.83 N
Normal brake bias : 40:60
 STEERING AND WHEEL 7
GEOMETRY
Ackerman Steering system COMPARISON OF OEMS
Steering Gear PARAME INFERN MARUTI SANTR
Centre steering TER
OS 800 O
Rack travel : 45mmTURNIN 3.025m 3.82m 4.1m
Lock to lock turns :3 G
Steering Ratio : 14:1 RADIUS
IBJ Centre distance : 9 inchi(deg) 37.30 44 42
OBJ centre distance : 18 inch
o(deg) 20.62 31.5 30
Tie rod length : 8 inch

Steering column
Collapsible Steering-Without Power
assist

Steering Wheel
Steering wheel Diameter - 12 inch
 POWER TRAIN 8
Engine power output = 7.45 KW at 3800rpm
Maximum torque obtained = 18.5 Nm at 2800 rpm
Acceleration = 8.06 m/s^2 (underdrive)
Transmission : Continuously Variable Transmission with ASM gear box.
Tyre size : 165/60 R12
Engine Speed: 1200 to 3800 RPM
GEAR RATIOS : The OEM selected POLARIS P90
ASM CVT with POLARIS ASM
Gear CVT Ratio High Total
Ratio GEARBOX
Underdrive 3.83 7.49 37.29271
Overdrive 0.76 7.49 7.40012
Reverse 3.83 5.11 25.44269
ASM
Gear CVT Ratio Low Total
Ratio
Underdrive 3.83 2.88 14.33952
Overdrive 0.76 2.88 2.84544
Reverse 3.83 5.11 25.44269
Tractiv High
GRADABILITY %
e Force Gear

availab Rati
le o
Spee Tractio
Gear
d n
Underdri 1737.0 The Gradability can be calculated
5.99
ve 9
Overdriv from the graph, which is 52%
53.57 352.24 (27) for this vehicle.
COST AND WEIGHT ANALYSIS-PIE
Cost Analysis CHART Weight Analysis
9

Roll Cage Engine

Roll Cage Engine CVT Gaerbox
Transmission suspension tires Rims
steering brakes Suspension Brakes
tyres and rims miscellaneous Steering Electricals
Miscellaneous
Particulars Estimate ()
Roll Cage 15000
Engine 20000 Estimated Weight
Particulars
(Kg)
CVT 20000
Roll Cage 66
Gaerbox 15000
tires 12000 Engine 30
Rims 6000 Transmission 25
Suspension 4000 Suspension 20
Brakes 20000 Steering 10
Steering 6500 Brakes 25
Electricals 5000 Tyres and Rims 36
Miscellaneous 25000 Miscellaneous 25
PROJECT PLAN 10
 VALIDATION PLAN & DFMEA 11
Failure mode Effects of failure Causes of failure severity
PLAN AND
DESIGN ACCEPTANCE RESUL Failure of joint Weight balance miss Impact in the side of 7

ANALYSIS between SIM the vehicle

ASPECT CRITERIA T and RRH

METHODOLOGY
ROLL

Failure of
Engine safety miss

Impact on rear side of
the vehicle

9
CAGE engine frame
SAE BAJA RULE Failure of steering, Impact in the front of
FEA Achieved
BOOK

Mounting point
suspension and
braking system
the vehicle
10

-ARTICLE 7 Front impact test No yield failure

Roll cage (front end)

Side impact test No yield

Rear impact test No yield


Gear oil

Heat accumulation in

Damaged oil seal,

6
Roll over No yield

leakage

gear box

improper mounting of
gear box


1) A suspension Engine/
Transmissi



No power

Worn out belts, low


analyzer software on


Slip of belt in
transmission

friction between belt
and clutch

8
(LOTUS CVT

SUSPENSION) shall Improper locking of
Drive shaft failure Transmission failure drive shaft
be used to

determine the

To provide good performance of the 8

Suspension damping without suspension system. Awaited



Damper failure No suspension effect

Worned out
spring/damper
5

failure 2 Load will be
Suspensio



No suspension effect




applied on the n


Mounting point

Poor fixture of hinges

10
vehicle in dynamic
failure No suspension effect



and static conditions
Stiffness Impoper matching
to test the misalignment between weight of the 8
vehicle and the spring
performance of the stiffness

suspension.


Failure of

Steering, suspension

Worned out ball joint

8
universal joint and braking system
The vehicle has failure

to move in Steering


Difficulty in Steering




straight path The system that Tie rod failure Damaged ball joints,
improper lengths of tie

7
when steering gives the required
rods

wheel is in centre turning radius and Air lock in soft brake pedal Leakage in brake fluid 9
Steering Awaited master
position and used the least steering Brakes cylinder
Brake failure Worned out brake hose
to turn the effort will be Leakage in 10

vehicle with selected. brake lining

 TEAM - INFERNOS 12
NAME RESPONSIBILITY
Thileepan. S Faculty advisor WORKSHOP
Team captain, Design
Ashwin. J
Head FACILITIES
Atheender. A Vice captain
CNC
Vertical
: Milling Center (VMC)
Vaikunth.B Power train head CNC Turing Center
Aravind. S
Suspension head, co- LATHE :
driver PL-4 Lathe
Dhilipan. R Steering head
Hariharan V.S. Braking head WELDING :
Gautam. M Driver , Testing TIG Welding
Ahilesh kumar N.S. Fabrication Head ARC Welding
Ajith kumar. S Fabrication
Ajith kumar. K Fabrication
DRILLING :
Dinesh kumar . S Fabrication Vertical drilling machine
Hari Krishnan. S Fabrication Power Drill
Gopinath. K Fabrication CUTTERS :
Arivalagan Fabrication
Ashwin S.V. Fabrication
Horizontal cutting machine
Jayabala . D Design GRINDING :
Madalapalle Prakash Design Surface grinding machine
Raghu Tharun Design Bench grinder
Arun kumar. P Marketing Head
Aravind Samy. N Marketing Cylindrical grinding
Bibin ipe. J Electrical
Harikrishnan.k Electrical
Suresh. R Electrical