CRIMSON THRUSTERS

Team ID: 14042

Anand Institute of Higher Technology

Presentation by :
Gowri Shanker.K
Hariharan.B
Rahul Dharmarajan
Srinivasan E.R

Design Methodology & Specifications

SI.NO

RULEBOOK
SPECIFICATIONS

MAX VALUES

CRIMSON
THRUSTERS

1.

Length, Width

108, 64

80,62

2.

3D space around driver

3.

SIM placement

8 to 14 from the seat.

10

4.

Drivers head clearance from

seat base

41

45

5.

Bend radius of the roll cage

member

6 to 28

10.5

6.

Fasteners

Bolts: Metric or Military

Metric 8.8

7.

Minimum pipe thickness

Primary: 0.120
Secondary: 0.035

0.12

8.

Minimum outside diameter of

pipe

Primary: 1
Secondary: 1

9.

Clearance between RRH and

seat

10.

Weight(with driver) (kg)

420kg

11.

Wheel base

58

12.

Maximum speed

60kmph

54.5kmph

13.

Ground Clearance

12.5

14

Tyre dimensions

25x8x12

Market Survey

Data Assumption

Design
Calculation

OEM Comprison
& Selection

Virtual Design

Analysis & Design

Validation

FEA

Completion

Roll Cage
All the members of the roll cage are made of SAE 4130 steel with OD 1 and wall thickness of .118
(3mm).

PROPERTIES OF MATERIAL:
Material
:SAE 4130
Yield strength
:600 N/mm2
Carbon composition :0.3%C(>0.18%C)
The total weight of the roll cage is estimated to be 62kg.
Total number of weld joints is 56
Maximum number of welds at a point is 2

The driver ergonomics for roll cage

Elbows to side impact member= 3.5
Drivers seat to fire wall(RRH)= 3
Drivers head to front bracing member= 15
Drivers helmet to top of the vehicle= 7
Overall roll cage length = 80
Wheel base = 59
Overall roll cage width = 42

Overall roll cage height = 54

Overall width = 58

Roll Cage
TEST

DETAILS

RESULTS

Max Stress(N/mm2)

224.332

FRONT
Load Applied(N)
20,000
IMPACT
TEST
Max Deflection(mm) 1.50883
FOS

2.7

Max Stress(N/mm2)

296.421

REAR
Load Applied(N)
20,000
IMPACT
TEST
Max Deflection(mm) 1.359
FOS

2.1

Max Stress(N/mm2)

284.399

SIDE
Load Applied(N)
13,000
IMPACT
TEST
Max Deflection(mm) 4.967
FOS

2.2

STRESS ANALYSIS

DISPLACEMENT

Roll Cage
TEST

ROLL
TEST

BUMP
TEST

DETAILS

RESULTS

Max
Stress(N/mm2)

328.304

Load Applied(N)

9,000

Max
Deflection(mm)

15.2842

FOS

Max
Stress(N/mm2)

313.525

Load Applied(N)

5,000

Max
Deflection(mm)

12.2493

FOS

STRESS ANALYSIS

DISPLACEMENT

100 % Ackermanns steering

Proposed track width = 54
Proposed wheel base = 58
Type of steering :
Rack and pinion
Maximum Angular travel
of steering wheel : 540o
Tie rod length = 9.889
Steering effort = 20 N

Steering set up Adams car

Parameter

Crimson
Thrusters

Maruti 800

37o

37o

26o

32o

Steering ratio

15 : 1

17 :1

Turning radius

3.133 m

4.4 m

Scrub radius Vs Steering angle

Brakes and Steering

Brake System

Steering Geometry
Caster

7o

Disc Brake

Camber

1o

4:1

4:1

Steering angle inner wheel

37o

19.05

22.25mm

19.05mm

Steering angle outer wheel

26o

Caliper Piston Effective

Diameter

42mm

43mm

42mm

Turning Radius

3.133m

Rotor Effective Diameter

230mm

230mm

230mm

Braking Force

3296.16 N

3257.399 N

4239.38 N

Stopping Distance

14.33m

14.5 m

11.145 m

Deceleration

0.8g

0.925g

1.028g

Parameters

Target

Santro

Omni

Type of Brake

Disc Brake

Disc Brake

Pedal Ratio

4:1

Diameter of Master
Cylinder

OEM Selected: Maruthi OMNIs Braking System

Weight Transferred: 208.43N
Dynamic load acting on front during braking: 2848.45 N
Dynamic load acting on rear during braking: 1271.74 N

Parameters

Front suspension

Rear suspension

Type

Unequal , parallel double

wishbone

Mac Pherson Strut

Wire diameter

9mm

Mean coil diameter

57 mm

Number of coils

11

Total length

322.63mm

540 mm

Lower wishbone or control arm

length

231.71mm

58.55mm

Upper wishbone length

208.8396mm

Inclination of wishbone wrt

ground

13.281o

1.413o

Caster angle

7o

0o

Camber

+1o

+1o

Scrub radius

5mm

5 mm

Spring stiffness

9 N/mm

9.8 N/mm

Motion ratio

2.4

2.61

Spring travel

62.5 mm

57.4 mm

9mm

12 mm
97 mm

Camber Vs wheel travel

Toe angle Vs wheel travel

Scrub radius Vs wheel travel

Drive Train
The power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way
Gear

Final
Gear
Ratio

Max
Tractive
Effort
(N)
2119.32

Final
Gear
Ratio

31.48

Max
Vehicle
Speed
(Kmph)
12.7

55.08

Max
Vehicle
Speed
(Kmph)
7.27

Max
Tractive
Effort
(N)
3708.14

First Gear
Second
Gear
Third Gear

18.70

21.4

1258.94

32.72

12.23

2202.80

11.40

35.11

767.48

19.95

20.06

1343.09

Fourth Gear

7.35

54.45

494.82

13.40

29.87

902.13

Reverse
Gear

55.08

7.27

3708.14

31.48

12.71

2119.32

Engine

Gearbox

Drive shaft

Stub axle
Engine working range (M) = 1750rpm3800rpm
Recommended maximum power (PM) = 6.7
KW at 3800rpm
To calculate power performance function
Pe = P1 e + P2 e2- P3 e3
P1 = PM/ M
P1 = 16.8455 /s
P2 = PM/ M2
P2 = .04235 /s
P3 = PM/ M3
P3 = 1.064 E-4 /s
Therefor power performance function is
Pe = 1608455 e + 0.04235 e2 1.064 E-4
e3

Wheels

Electrical Circuit

Ergonomics and Validation

ERGONOMIC
PARAMETER

VALUES

Visibility

67

Front visibility distance

61.59

Seat rest angle

20

Cock pit length

79.48

Cock pit height

53

Design Aspect
Roll Cage

Criteria
SAE BAJA Rule Book Section 3

Plan and Analysis Methodology

FEA :

Front Impact Test

Side Impact Test

Rear Impact Test

Roll over

Result
Achieved
Below yield stress
Below yield stress
Below yield stress
Below yield stress

Suspension

To provide good cushioning against shocks, without

failure.

1. ADAMS shall be used to determine the performance

of the suspension.
2. Load will be applied on the vehicle in dynamic and
static conditions to test the performance of the
suspension.

Achieved

Steering

To design a steering mechanism which satisfies

Ackermanns mechanism and also provide self centering
effect and avoids nervousness.
To design a braking system which provides comfortable
stop at a distance of 14.3m

The system that gives the required turning radius and

the least steering effect will be selected.

Achieved

The system that gives stopping distance closest to 11.14

m and best suitable will be selected.

Achieved

To increase the torque and speed of the vehicle to meet

the demands of the hill climbing test.
To provide fool proof lighting and sound circuits

To select the required gear ratio, which gives torque and

speed.
To design the kill switch and the various circuitry

Achieved

Brakes
Transmission
Electricals

Achieved

Co-Ordinates and Innovations

The centre of gravity for the entire vehicle is located at
(995,189,-1050) which is below the seat

INNOVATIONS:
Fly ash incorporation in brakes
Piezo Electric power generation
Roll cage diameter optimization

Component

(X,Y,Z Coordinates)

Weight (kg)

Engine

(339,316,-1230)

30

Gearbox

(247,307,-851)

15

Seat

(671,566,-1050)

Driver

(973,529,-1100)

80

Steering

(1550,502,-1050)

Back Right Brake

(314.6,163,-162)

1.265

Back Left Brake

(311,163,-1950)

1.265

Front Right Brake

(1780,165,-296)

1.265

Front Left Brake

(1780,165,-181)

1.265

Back Right Tyre

(314.6,158,-112)

20.246

Back Left Tyre

(315,158,-1960)

20.246

Front Right Tyre

(1780,158,-286)

20.246

Front Left tyre

(1780,158,-1820)

20.246

Front Right Suspension

(306,367,-430)

1.2985

Front Left Suspension

(306,367,-1600)

1.2985

Back Right Suspension

(1790,337,-585)

.5234

Back Left Suspension

(1790,337,-1520)

.5234

Brake Pedal

(1730,132,-1090)

.586

Clutch Pedal

(1730,132,-981)

.586

Acceleration Pedal

(173,132,-878)

.586

Team Faculty Advisor : Dhanasekhar

Team Captain
: Mohammed Zaid
S.No

Name

Role in Team

Aravindh

Machinist / Brake

Adithyan

Design / Administration

Harish

Inspection / Machinist

Harikrishnan

Co-Driver / machinist

Arun

Electrician

Benraja

Design

Madumitha

Machinist / Steering

Sahithya Sabari Gireesh

Design / Welding

Pawan Kumar

Inspection / Machinist

10

Sai Vishnu

Machinist / Administration

11

Gowri Shanker

Design / Welding

12

Dhivaker

Machinist / Driver

13

Mohammed Zaid

Stocker / Machinist

14

Manikandan

Inspection / machinist

15

Mahendran

Machinist

16

Mohammed Mudassir

Machinist / Stocker

17

Hariharan

Machinist / Stocker

18

Manoj Somoosay

Machinist / Steering

19

Varun

Inspection / Stocker

20

Vaisikan

Electrician

21

Rahul Dharmarajan

Design / suspension

22

Vaishnavi

Machinist / Suspension

23

Srinivasan

Machinist / Steering

24

Soorya

Machinist / Brakes

25

Deepak

Welding