Presents

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Market

Availability of Resources

Design Optimization Parameters

Selection of Resources

Design Approach
Designing Analysis and Synthesis

Subsystem Properties

Optimization Optimized Design Revaluation And Fool-Proofing

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Cost, Ergonomics Parameters

Performance

Final Product

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S No 1 2 3

RULES Capability of carrying one person 190.3 cm (63) tall weighing 113.4 kg (250 lb). Width: 162.56 cm (64 in) and Length: 108 inches end to end At least 3 inches(76 mm) clearance from the envelope created by the structure of the car. Head restraint must be provided on the car to limit rearward motion of the head in case of an accident. Shake resistant Drip pan and Splash shields on tank Tie Rod Protection

REMARK Followed Followed Followed

Followed

5 6

Followed Followed

Design Parameter Constraints as per Rulebook

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Wheelbase Track Width: Ground Clearance Weight:

71.54 56 (Front, Rear) 15 330kg

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Steel AISI 1018

( for Roll Cage Members)

Length :41m Outer diameter :1 Thickness : 3mm

Sheet Metal ASTM A653 ( for Base Members)

Thickness 0.8mm Area 3 sq. meter

ABS Sheet

(for Body Panels)

Thickness 3mm Area 4 sq. meter

Padding Foam

( for Roll Cage members )

Length 7m

AISI 4130
Specifications Weight/Length (kg/m) Length used (m) Total weight (kg) Cost /kg( Rs.) 1.25 OD with 3 mm thick 1.45 41 59.45 275

AISI 1018
1 OD with 3 mm thick 1.64 41 67.24 140
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AISI 1018 is finalized as the material to be used for the chassis and the Roll cage. AISI 4130 dropped because there is minor weight difference between AISI 1018 and AISI 4130 but Cost of AISI 4130 was approximately double. AISI 4130 requires pre heating and post quenching when welded.

The Spring Values Derived from: Bullet Electra(Front & Rear Both)

Double wishbone type Suspension mounted.

Formulas Used For Spring Selection Parameter Spring Const (N/mm) IR (Installation Ratio) MR (Motion Ratio) Inclination (alpha) (deg) Reference Book: The Automotive Chassis Front 28 0.6 0.657 25 Rear 28 0.36 0.38 20

The Steering system is derived from : TATA Nano

Rack and Pinion Properties: Rack travel Steering ratio Length Of tie-rods OBJ to OBJ distance No. of turns( lock to lock) : : : : : 51.60 mm 15.1 : 1 390mm 1146mm 3.32

Turning Radius of the vehicle is 2.32m

Positive Ackermann is followed with Ackermann Percentage : 96%

Reference Book: Fundamental Of Vehicle Dynamics

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Pre-processing to define the model geometry The load is decided using the impulse momentum theorem:

Initial Model According To Rulebook

Final Result

Defining Element type and Material properties using E = 200 GPa , v = 0.29

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Resultant FOS

2.86

2.73

Front Impact Analysis

Rear Impact Analysis

3.03

2.95

Rollover Impact Analysis

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Side Impact Analysis

Brakes: Disc Brakes (Front And Rear) Specifications: Braking System: Maruti 800 Tandem master cylinder and Disc Caliper assembly Braking Effort: 250 N Performance: Torque Required Torque Developed Clamping Force Stopping Distance Cross Braking System : 420.63 Nm : 520.65Nm : 632.40 N : 4.37m

Battery Used : Dry Type (12 V- 44 Ah) Complete Head and Rear Light ,Side Indicator, Reversing Lights system installed. Independent Fuse for different components. Kill Switches routed for full vehicle except lights.

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Engine Used Briggs & Stratton Power 10 hp OHV Intake Governor Settings 3800 rpm Transmission Used : Mahindra Alpha

Transmission Gear No. 1 2 3 4 Reverse

Gear Ratio 31.48 18.7 11.4 7.35 55.08

Top Speed(km/hr) 13.25 22.31 36.60 56.88 7.57

Coupling Used :

Axles Used : Axles of Alpha and Maruti 800 will be

friction welded to form our custom axles. Maruti 800 parts are used because of cheap and easily available standard parts.

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Tyre Specification : Outer Diameter 23 Track Width 8 No. of plies 6 Rim Diameter 12 Aspect Ratio 1.45:1

SEV Severity DET Detection

OCC Occurrence RPN - SEVxOCCxDET

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S No. 1

Parameter Wishbones Impact Failure & Stress Failure

Methodology of Testing Vehicle to be driven on various terrains like muddy,stony, slurry, gradiants for stress testing Vehicle to be driven on zigzag track having bumps like s-bend, 90degree bend, U bend etc Testing track to be prepared having a radius of 2 m Vehicle to be driven on various terrains like muddy, stony, slurry, gradients for engine failure Vehicle to be driven on various terrains like muddy, stony, slurry, gradients for power train failure Vehicle to be driven on bumpy track for 200mm bump and 100 mm rebound Inspect disc mountings before driving the vehicle and tighten all nut bolts Check the pads after 1000km and replace if needed By using Anti-Puncture Sealing fluid Vehicle to be run on a 45degree sideways incline and check for fuel spill over Pollution check of vehicle to be done Team RAFTAAR

2 3 4

Steering-Tie Rod or Rack Turning Circle Diameter Engine Failure

5 6 7 8 9 10 11

Gear box Failure Damper failure Brake Disc Loose Brake Pad Failure Tyre Puncture Fuel Tank spill over Emissions

Low Centre of Gravity ensures minimal chances of roll over of the vehicle Flexible PVC Piping protects all the electrical wires from short circuiting. Front and Rear Bumpers are provided to safeguard in the event of rear and front collisions. Five point racing Harness is attached to the most rigid and structural roll cage members. Insulated Battery Cover is Provided to avoid short circuit and to secure its coordinates.

Parameter Seat angles Knee angle Ankle angle Elbow angle 80 Upper arm angle

Ergonomic Range 95-100 for alert 110-120 for strength 90-100 for comfort 80-165 for comfort 0-35 for comfort

Design Values 99 104 96 108 10

Driver Can See Road, Speedometer Fuel Indicator and Rear View In Mirror at Same Time.

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Sr. No. 1. 2. 3. 4. 5.

Item Steering And Suspension Roll cage and Mountings Power Trains And Tire Assembly Customized Seat Miscellaneous Total

Price(in Rs) 20,000 30,000 60,000 5,000 45,000 1,60,000

Estimated Total Cost : Rs 1,60,000/-

Gulshan Bansal & Co. Plot No 377, Indl. Area, Phase 1, Panchkula

T.G. Steels & Scaffolds S.C.O-4, Wadhava Nagar, Zirakpur, (Punjab).

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