Proposed Aggregates for SAE BAJA-2014

ACADEMY OF BUSINESS AND ENGINEERING SCIENCES

GHAZIABAD (U.P)

To design, build and race off-road vehicles for an imaginary firm which are manufacturable to withstand the harshest elements of rough terrain. Cost Effective The vehicle must be safe, easily transported, easily maintained and fun to drive. It should be able to negotiate rough terrain without damage.

CONFORMATION UNDER SAE RULES

DRIVER EXIT TIME LESS THAN 5 SECONDS

TARGET KERB WEIGHT LESS THAN 300kg

TOP SPEED OF 60 km/hr

TURNING RADIUS LESS THAN 8 FEETS

OPTIMUM GRADIENT

 ORIGINALITY

INNOVATION
SAFETY

SPACIOUS COCKPIT
MANEUVERABILITY

AESTHETICALLY PLEASING

SKETCHING

DIMENSIONING OF ROLL CAGE

MODELING

MATERIAL SELECTION

FINITE ELEMENT ANALYSIS

AGGREGATES SELECTION

SIMULATION

TRANSMISSION SUSPENSION
WHEELS AND TYRES STEERING BRAKES

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Siddharth Garkhail Rahul Mahajan Nawanit Singh Yadav Atin Kumar Amit Pandey Shubham Singhal Gaurav Kumar Satendra Kumar Shubham Kansal Sandeep Kumar Jha Nipun Sabharwal Anurag Gupta Ashwarya Singh Manoranjan Pandey Aviral Yadav Rahul Kaushik Tushar Thakral Farheen Siddiqui Praveen Shahi Manish Kumar Singh Sonali Acharya Sandeep Kumar Damodar Deepak Singh Attri Monika Srivastav

DEPARTMENTAL HEADS: DESIGNING: ENGINE & TRANSMISSION: SUSPENSION: STEERING: BRAKES & TIRES: DOCUMENTATION: ELECTRICAL: Siddharth Anurag Nipun Rahul Satendra Sonali praveen

Material Selection:
There mainly three types : 1) DOM 2) CDS 3)ERW ERW ERW stands for electrical resistance welded pipe. A plate rolled to become a pipe and welded using electric resistance welding process. Used for only high diameter and not as strong as DOM thus not suitable for SAE

DOM
DOM stands for Drawn Over Mandrel . DOM is a cold drawn electric resistance welded tube with all the flash removed prior to cold drawing. DOM tubing produces more accurate O.D. and I.D. Tolerance as compared to others. Has high tensile and yield strength and gives clean I.D. and O.D. surfaces. DOM are called to be seamless but they are not technically seamless since during manufacturing process the weld line becomes nearly undetectable. Suitable for SAE.

CDS
CDS is a cold drawn steel tube which offers uniform tolerances enhanced machinability and increased strength and tolerances. Superior surface finish , dimensional accuracy and excellent microstructure uniformity. Also suitable for SAE. Since DOM is cheaper as compared to CDS with exactly the same properties so we opt for DOM.

DOM OVER OTHER

The machining qualities of DOM tubing are similar to that of seamless tubing of the same size and analysis. But, it has higher strength and excellent machinability. DOM is cheaper. ( INR 145 per square feet)

ROLL CAGE MATERIALS

There are many materials that can be used, some of them are : Carbon steel Mild steel Chrome molybdenum steel 1018 mild steel 1020 mild steel 4130 chromoly But with SAE compliance we can use mild steel and low alloy steel so the suitable ones are 1018 , 1020 , 4130 chromoly.

COMPARISON
Material
1020 MS Yield Strength (Mpa) 165 Modulus of elasticity (Gpa) 200 Carbon Content (%) 0.20 Density (g/cm3) 7.87 Wall thickness (inches) 0.113

1018 MS

365

205

0.28 -0.33

7.85

0.104

4130 chromoly

435

205

0.30

7.85

0.083

1026 CS

415

210

0.22-0.28

7.858

Rulebook

----

-----

0.18

-----

0.062

 4130 chromoly is more stronger than mild steel and that allows chromoly to be a thinner wall tubing.
1020MS is less expensive than 4130 chromoly but comes with the disadvantage of more weight. 1020MS will increase the weight about 50-60 pound heavier than the 4130chromoly and nearly double the price. Since in compliance with SAE we can compromise with cost but not with weight so we must opt for 4130 chromoly. 4130 requires TIG welding .

1.1 Material used The material we used in our 2012 Baja vehicle is ASTM 106 , grade B ,carbon content 0.25% and yield strength 364 Mpa Its available in Ghaziabad at following shops a. Bharat pipe b. Haryana pipe company Other option available to us are AISI 1018, AISI 1020,AISI 4130 These are available in Delhi at the following shop a. Sidhant metals

INITIAL SKETCKES :
1. 2.

3.

Roll Cage 2012-13

Praposed Roll Cages for baja 2014

Finalized Roll Cage for SAE BAJA 2014

SIDE VIEW

FRONT VIEW

TOP VIEW

ISOMETRIC VIEW

REAR VIEW

COMPARISON

2012-2013 3.7 2.54 2.05

2013-2014 1.82 1.07 1.8

Comparison
2012-2013

F.O.S (front) F.O.S (rear) F.O.S (side)

Front impact load:

Side impact load:

16000 N
8000 N

30000 N
15000 N

2013-2014

Wider cockpit for more comfort ride. Inclined SIM for the fast exit of driver. Rear compartment modified to give more asthetic look and to provide a utility compartment. Raised RHO at the front. Appropriate space for ABC mounting.

FEA (front impact)

FOS=1.8

FEA (rear impact)

FOS=1.1

FEA (Side impact):

FOS=1.7

 Compatible gear ratios Maximum speed is 60 km/hr ATV is all about higher torques and less speed Less expensive than CVT.

1. Clutch 2. Gear box 3. Differential

Overall gear ratios Reverse First Second Third Fourth 55.08:1 31.48:1 18.70:1 11.40:1 7.35:1

Why Flange Coupling??

FLANGE COUPLING BELT DRIVE

Larger torque range(25 KNm 1310 KNm Easily assembled and dismantled Low cost Available in standard sizes Friction losses are lesser than belt or chain drive

Speed ratio not constant Heat accumulation COG moves up

Why manual transmission over CVT??

MANUAL TRANSMISSION CVTs

Mechanical efficiency is better than belts Couples to engine with a rigid clutch Better fuel economy

Based on strength of belts or chain Costly Noisy Transmitting motion by friction causes wear

ENGINE:
BRIGGS & STRATTON MODEL 200000

Bore: 3.120 in (79.23 mm) Stroke: 2.438 in (61.67 mm) Spark Plug Gap: 0.030 in (0.76mm) Intake: 0.004 0.006 in (0.10-0.15 mm) Exhaust: 0.004 0.006 in (0.10-0.15 mm)

ENGINE (continued):
Single Cylinder Four Stroke, 305cc Over Head Valve (OHV) Compression Ratio: 8.0 : 1 Engine Ideal RPM is set to 1750 rpm Weight: 29.10 Kgs Governor RPM: 3800 rpm

BRAKES:
Rules require two independent hydraulic systems
DISC BRAKES WITH VENTED DISC:

Advantages :
Good resistance to brake fade Better braking efficiency High performance torque Lesser stopping distance than drum brakes Less wear and tear Good dissipation of heat Light in weight

Types Of Master cylinder

Single cylinder, dammed reservoir

Pros: simple, packaging flexibility Cons: longer than dual cylinders

Dual cylinders, overhead mount

Pros: shortest overall length Cons: aesthetics

Dual cylinders, floor mount

Pros: elegant packaging Cons: longer, may conflict with steering components

Proposed brake assembly:

Maruti 800 disc brake assembly

STEERING
We are using rack and pinion of TATA Nano. We will customize the pinion to center position on rack. Hence, we will be able to use equal tie-rods. Ackermann steering geometry. Tie rod lengths = 12.59 inc keeping ball joint position 1 feet from the rack

The turning radius is calculated as 3.45 m (approx)

Rack and Pinion Steering

Simplified system

Light
Ease of integration with suspension

Proposed steering for SAE BAJA 2014:

The proposed steering for our ATV will be a FourWheel Steering system because: Minimum turning radius. Maneuverability increases. This will be helpful in maneuverability test and figure of eight test.

SUSPENSION
We will be using double wishbone suspensions in front and rear.
REASON: We can get maximum travel by placing it at almost 90 degrees We can arrange the values of caster & camber angle as per our requirements Steering effort is very less as compared to Mcpherson strut

We will be using MONORE suspensions in front and TATA Indica suspensions after customization, in rear. We will be installing a tender spring to maximize the suspension efficiency, that is, our vehicle will not produce jerks on application of small loads.

SPECIFICATIONS (FRONT):
WIRE DIAMERTER: 9 mm OUTER DIAMETER: 100 mm NUMBER OF ACTIVE COILS: 8 LENGTH: 482.6 mm SPRING INDEX: 10.11 MODULUS OF RIGIDITY: 85 GPa STIFNESS: 11.56~12 N/mm

SPECIFICATIONS (REAR):
TENDER SPRING:
Max. force=300 N (assumed) Stiffness=10 Deflection=30 mm No. of active coils=7 Wire diameter, d=7 mm Mean coil diameter, D=71 mm Length of spring=84 mm

MAIN COIL SPRING:

Max. force=1500 N (assumed) Stiffness=19 Deflection=75 mm No. of active coils=5 Wire diameter, d=9 mm Mean coil diameter, D=90 mm Length of spring=220 mm

FRONT SUSPENSION (MONORE)

REAR SUSPENSION (INDICA)

TIRES SPECIFICATION
Front Tire: Overall Diameter- 25 inches Section Width 8.0 inches Front Tire Rear Tire: Overall Diameter- 26 inches Section Width 10.0 inches

Rear Tire

CENTER OF GRAVITY CALCULATIONS:

S.No. COMPONENT DRIVER ENGINE TRANSMISSION WEIGHT (Kg) 70 30 17 X (cm) 92 153 153 Y(cm) 0 13 -9 Z(cm) 5.08 20.32 2.54

1.
2. 3.

4. 5.
6. 7. 8. 9.

FUEL TANK HALF SHAFTS (REAR)

ROLL CAGE RACK Front tyre Rear tyre

5 6
66 7 40 40

120 175
84 0 0 175

-25 0
0 0 0 0

71.14 -2.54
35.56 0 -22.86 -22.86

10.
11.

FRONT SUSPENSION
REAR SUSPENSION

10
16

0
162.3

0
0

20.32
30.48

NET WEIGHT OF ATV IS: 307 KG

X=
((70x92)+(30x153)+(17x153)+(5x20)+(6x175)+(66x84)+(16x162.3)+(40x175))
307

=100.97 ~ 101 cm Y= ((30x13)+(17x(-9))+(5x(-25) 307 =0.36 cm

Z= ((70x5.08)+(30x20.32)+(17x2.54)+(5x71.14)+
(6x(-2.54))+(66x35.56)+(10x20.32)+(16x30.48)+(40x2x(-22.86)) 307 =8.33 cm Considering the origin to be the center front axle. The height of COG from ground is (8.33+22.86) = 31.19cm

ELECTRICAL AND ELECTRONICS

Other Accessories:

BRAKE LIGHT The vehicle must be equipped with a red brake light. When the break is applied the wire get shorted, results in the completion of the circuit and the break light get SWITCH ON.

REVERSE ALARM and LIGHT The vehicle must be equipped with a reverse alarm and light. Amber colour, visible at a minimum distance of 10 meters from vehicle.

THE BATTERY:
Battery is the main Part of the electrical system in an Automobile. The Battery supplies current for operation of the starting motor and ignition system. The Battery used in our ATV would be of the rating 12V/44 Ah.

LIGHTNING AND WIRING:

Main battery feed circuit Main charging Circuit Field Circuit - 44/0.012 - 23/0.012 - 14/0.012

KILL SWITCH:
Each vehicle must be equipped with two (2) easily accessible kill switches to push off the ignition and the entire electrical system of the car.

TESTS
ACCELERATION TEST BRAKE TEST MANEUVERABILITY TEST

RUN 1 2 3

RESULT

HILL CLIMB TEST TURNING TEST OFF ROAD TEST LAP TIME TEST

DESCRIPTION OF TASKS FOR SAE BAJA 2014 (VIRTUAL PHASE)

Task No. Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Task 11 Task 12 Task 13 Task 14 Task 15 Start Date 1-Mar-13 21-Mar-13 1-Apr-13 11-Apr-13 19-Apr-13 22-Apr-13 11-Apr-13 27-Apr-13 11-Jun-13 21-Jun-13 1-Apr-13 11-Jun-13 21-Jun-13 26-Jun-13 6-Jul-13 Duration 20 10 10 8 3 5 7 1 10 5 25 15 5 11 10 Task Description Selection of Team Intro. Meetings+fund collection+signing undertakings+membership forms Sketches for rollcage design Preliminary solid work modelling FEA on solid works Finalised rollcage Material Selection Preliminary presentation PVC modelling & amending rollcage on solid works + analysis on ANSYS 1:5 Scale Model R&D for selection of diff. aggregates Finalising the aggregates , innovation, ppt preparation Call for Scholarship Final Presentation Completion Practice for Virtual Round

GANTT CHART FOR SAE-BAJA 2014 (VIRTUAL PHASE):

1-Mar-13 Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 21-Mar-13 10-Apr-13 30-Apr-13 20-May-13 9-Jun-13 29-Jun-13 19-Jul-13 8-Aug-13

Task 7
Task 8 Task 9 Task 10 Task 11 Task 12 Task 13 Task 14 Task 15

DESCRIPTION OF TASKS FOR SAE BAJA 2014 (MANUFACTURING PHASE):

Task No. Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Start Date 1-Sep-13 16-Sep-13 18-Sep-13 23-Sep-13 25-Sep-13 23-Sep-13 25-Sep-13 Duration 15 7 5 2 3 2 6 Task Name Marketing & Arrival of Material Rollcage Fabrication Double A-arm manufacturing Brake cylinder , steering, rack & pinion brackets Engine mounting & suspension bracket Double A-arm mounting Double A-arm assembly & ball joint , knuckle + tire+ brake disc calliper mounting

Task 8
Task 9 Task 10 Task 11 Task 12 Task 13 Task 14 Task 15 Task 16 Task 17 Task 18

1-Oct-13
2-Oct-13 6-Oct-13 11-Oct-13 14-Oct-13 17-Oct-13 18-Oct-13 22-Oct-13 29-Oct-13 1-Nov-13 8-Nov-13

1
4 5 3 3 1 7 7 3 7 2

Brake cylinder assembly

Steering rack assembly Steering mounting and ackermann config. Shocker assembly mounting Engine + transmission mounting Lubrication Vehicle testing & adjustment Electric mechanism mounting Sheet metal cutting and riveting Final testing and adjustment Paint

GANTT CHART FOR SAE-BAJA 2014 (MANUFACTURING PHASE):