VIRTUAL BAJA SAE INDIA 2012

DESIGN PRESENTATION

Team THE KRIEGER

Team ID 35809
VELAMMAL ENGINEERING COLLEGE, Chennai

DESIGN METHODOLOGY & ACHIEVED SPECIFICATIONS

THE KRIEGER

SPECIFICATIONS

S.NO

PARTICULARS

1.

Track Width

54

2.

Wheel Base

66

3.

Maximum Width
Of The Vehicle

62

4.

Maximum Length
Of The Vehicle

100

5.

Ground Clearance

306.81mm (12.07)

6.

Turning Radius

3.41m

7.

Caster

+6:

0:

8.

Camber

+2:

+2:

9.

Toe

0mm

0mm

10.

Scrub Radius

4.6mm

4.6mm

11.

Wheel Travel

200mm

200mm

12.

Maximum Speed

53.57 km/hr

13.

Maximum Grade

44.690

14.

Stopping Distance

15.642 m
(from 60 km/hr to rest)

REAR

FRONT

ROLL CAGE
All the members of the roll cage are made of
SAE 1541 steel with OD 1 and wall thickness
Of 3mm.

ROLL CAGE AND OVERALL MANAGEMENT

PRAVEEN A S

A1

CAPTAIN, FABRICATION HEAD

SARATH VISHNU U

A2

VICE CAPTAIN

KARTHIKEYAN P

A3

DRIVER,TESTING

NAVIN KUMAR V R

A4

ACCOUNTS,CO-DRIVER 2

ASWIN N

A5

FABRICATION

PROPERTIES OF MATERIAL:
Material
:SAE 1541
Yield strength
:800 N/mm2
Carbon composition
:0.415 %C
The total weight of the roll cage is estimated to be 57kg.
Total number of weld joints is 62
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 = 96
Overall roll cage width = 31
Overall roll cage height = 50

Wheel base = 66
Track width = 54
Overall width = 62
THE KRIEGER

ROLL CAGE
TEST

DETAILS

Max stress(N/mm2)
Front
impact

Side
Impact

PRE PROCESS

331.951

Load applied (N)

20900

Max deflection(mm)

4.165

FOS

2.409

Max stress(N/mm2)
Rear
impact

RESULT

350.119

Load applied (N)

20900

Max deflection(mm)

4.496

FOS

2.284

Max stress(N/mm2)

397.72

Load applied (N)

20900

Max deflection(mm)

13.769

FOS

2.011
THE KRIEGER

STRESS
ANALYSIS

DEFLECTION

ROLL CAGE
TEST

DETAILS

RESULT

Max stress(N/mm2)

285.27

Load applied (N)

20900

Max deflection(mm)

4.476

FOS

2.80

PRE PROCESS

Roll over

Max stress(N/mm2)
Front
bump

Load applied (N)

Max deflection(mm)
FOS
Max stress(N/mm2)

Rear
bump

Load applied (N)

Max deflection(mm)
FOS

207.718
1800
10.047
3.85
277.245
2200
17.041
2.88
THE KRIEGER

STRESS
ANALYSIS

DEFLECTION

STEERING
STEERING SYSTEM

100% Ackermanns steering.

Proposed track width= 54
Proposed wheel base= 66

SUBRAMANIAN S

B1

DESIGN ENGINEER

JAYAVEL R

B2

FABRICATION

VIJAI KRISHNA T

B3

FABRICATION

VENKAT RAM R

B4

PURCHASE

STEERING SETUP ADAMS CAR

PARAMETERS

Krieger

Indica

350

30.370

240

20.560

Steering ratio

16:1

19.37:1

Turning radius

3.07m

3.41m

SCRUB RADIUS VS WHEEL STEER ANGLE

Type of steering Rack and Pinion

Max angular travel of steering wheel=5400
Tie rod length=13.38
Steering Effort = 20N

THE KRIEGER

SUSPENSION
PARAMETERS

FRONT SUSPENSION

REAR SUSPENSION

Unequal, Parallel, Double

wishbone

Unequal, parallel, Double

wishbone

Wire diameter

8.5mm

10mm

Mean coil diameter

75mm

75mm

16

20

Total length

545mm

545mm

Suspension travel

71mm

78mm

Spring rate

8N/mm

9.8N/mm

Ford ikon

Ford ikon

Lower wishbone length

342mm

342mm

Upper wishbone length

256.21mm

256.21mm

Angle of wishbones with respect to ground

200

200

Caster angle

+60

nil

Camber angle

+20

+20

Scrub radius

4.6mm

4.6mm

Height of roll center

250mm

250mm

2.5

2.8

Type

Number of coils

Best suited shock absorber

Motion ratio
THE KRIEGER

SUSPENSION ANALYSIS
FRONT

FRONT
SUSPENSION PARAMETERS

CAMBER CHANGE
TOE CHANGE
SCRUB RADIUS

PARALLEL WHEEL TRAVEL (IN MM)

-100
-1.372
0.961
2.716

-50
1.4
-0.1
3.776

LEFT
0
1.843
-0.13
4.633

-50
1.4
0
3.78

LEFT
0
1.84
-0.1
4.633

SUSPENSION PARAMETERS

CAMBER CHANGE
TOE CHANGE
SCRUB RADIUS

50
1.468
0.06
5.495

100
0.6542
0.379
7.467

-100
-1.372
0.961
2.716

-50
1.4
-0.1
3.776

RIGHT
0
1.843
-0.13
4.633

50
1.468
0.06
5.495

100
0.6542
0.379
7.467

RIGHT
0
1.84
-0.1
4.633

50
1.468
0
5.492

100
-1.12
1.04
7.415

OPPOSITE WHEEL TRAVEL (IN MM)

-100
-1.1
1.04
2.736

50
1.36
0.003
5.492

100
0.5
0.19
7.415

-100
0.508
0.19
2.736

-50
1.415
0.003
3.78

REAR
SUSPENSION PARAMETERS

CAMBER CHANGE
TOE CHANGE
SCRUB RADIUS

-100
-1.372
0.961
2.425

-50
1.4
-0.1
4.11

-50
1.38
0.033
4.1064

LEFT
0
1.86
-0.1
4.3642

SUSPENSION PARAMETERS

CAMBER CHANGE
TOE CHANGE
SCRUB RADIUS

REAR

PARALLEL WHEEL TRAVEL (IN MM)

LEFT
0
1.843
-0.13
4.3642

50
1.468
0.06
4.0109

100
0.6542
0.379
3.47

-100
-1.372
0.961
2.425

-50
1.4
-0.1
4.11

RIGHT
0
1.843
-0.13
4.3642

50
1.468
0.06
4.0109

100
0.6542
0.379
3.47

RIGHT
0
1.86
-0.1
4.3642

50
1.38
0.033
4.1064

100
-1.32
0.2508
2.3975

OPPOSITE WHEEL TRAVEL (IN MM)

-100
-1.32
0.2508
2.3975

CAMBER VS WHEEL TRAVEL

50
1.5366
-0.1
4.0184

100
0.7842
0.841
3.4863

-100
0.7842
0.841
3.4863

-50
1.5366
-0.1
4.0184

SCRUB RADIUS VS WHEEL TRAVEL

SUSPENSION SYSTEM

THE KRIEGER

PRAVEEN KUMAR K

C1

DESIGN ENGINEER

VARUN M

C2

DESIGN HEAD

JAMES J

C3

FABRICATION

SHRAVAN KESSAV S

C4

MARKETING

RAHUL S P

C5

PURCHASE

BRAKES
BRAKES

Braking effort (Driver on pedal)=22kgf

Target stopping distance= 17.7m (from 60 km/hr to rest)
Target braking force= 2746.8 N
COMPARISON OF OEMS

JOASH S

D1

DESIGN ENGINEER

CHAITANYA UMAMAHESH K

D2

FABRICATION

NAGARAJAN T

D3

FABRICATION, TESTING

PRASANTH J N

D4

FABRICATION

VIGNESHWAR V

D5

PURCHASE

PARAMETERS

SANTRO

OMNI

Pedal ratio

3:1

3:1

Diameter of master cylinder

22.25mm

19.05mm

Caliper piston effective

diameter

43mm

42mm

Rotor effective diameter

230mm

230mm

Braking force

2278.94 N

3108.88 N

Stopping distance
21.34 m
15.642m
OEM Selected: MARUTHI OMNIS braking system.
Weight transferred: 500.82 N
Dynamic load acting on front during braking=2045.89 N
Dynamic load acting on rear during braking =1387.60 N
THE KRIEGER

TWIN MASTER CYLINDER

BRAKE BIASING

DRIVE TRAIN
Engine power output =7.46kW at 3800rpm
Corresponding power performance function P = 16.84e +0.0423 e2 -1.063*10-4 e3
Corresponding output torque T = 16.84+0.0423e-1.063*10-4 e2
Wheel Radius = 0.2794m , Engine Range 1800rpmN3800rpm
Mass of the vehicle= 350kg and max allowable speed= 60 km/hr

GEAR RATIO

Chain drive ratio 1:1

Alfa Gear box

Load:12000N
Pitch:12.7
Chain number : D 084 01
Tensile strength : 1270 kgf

First

4.6

Second

2.73

Third

1.667

Fourth

1.074

Secondary gear box

High gear
Low Gear

DRIVE TRAIN

0.8
1.58
THE KRIEGER

DEEPAK BALAJI H

E1

DESIGN ENGINEER

JAGANATH K

E2

FABRICATION

ANBAZHAGAN M

E3

FABRICATION

KAASI PRASAATH V B

E4

CO DRIVER 1, TESTING

VENKAT NARAYANAN V

E5

PURCHASE

DRIVE TRAIN
Speed comparison
60
50
Speed Km/hr

Maximum speed obtained on engaging the

speed gear is 53.57km/hr.
Maximum grade obtained on engaging the
grade gear is 44.690.
Maximum traction force obtained is
2427.85N.
Maximum torque obtained at the wheels is
976.86N-m

40
30
20
10
0

Grade gear
engagement

6.843

11.53

18.88

34.52

Speed gear
engagement

12.51

21.08

34.52

53.57

Direct coupling

10.8

18.216

29.8386

42.696

Torque comparison

Grade comparison

1000
Grade ()

Torque (Nm)

1200
800
600
400

200
0

50
45
40
35
30
25
20
15
10
5
0

Grade gear
engagement

44.69

27.96

16.63

10.63

115.48

Speed gear
engagement

24.8

16.04

9.71

6.24

144.35

Direct coupling

31.08

17.84

10.78

6.92

Grade gear engagement

976.86

579.75

354.01

228.08

Speed gear
engagement

494.61

293.54

179.24

Direct coupling

618.27

366.93

224.05

THE KRIEGER

SAFETY, BODY AND ELECTRICAL

The center of gravity for
the entire vehicle is located
at (1300, -441, 865.75)
which is below the seat

start

Drivers Safety
System

Circuit on
Component
Engine
Transmission
Steering Rack
Steering Column
Pedal
Seat + Driver
Front Left Hub + Wheel
Front Right Hub + Wheel
Rear Left Hub + Wheel
Rear Right Hub + Wheel
Roll Cage
Front Left Upper A Arm
Front Left Lower A Arm
Front Right Upper A Arm
Front Right Lower A Arm
Rear Left Upper A Arm
Rear Left Lower A Arm
Rear Right Upper A Arm
Rear Right Lower A Arm
Front Left Strut With Shock
Front Right Strut With Shock
Rear Left Strut With Shock
Rear Right Strut With Shock

(X,Y,Z Coordinates) Weight (kg)

(2135,-570,190)
30
(2135,-350,220)
18
(435,-190,60)
4
(145,-365,65)
2.5
(584,-286,95.5)
7
(1360,-460,62.5)
80
(326,-396,-100)
19.894
(326,-396,1250)
19.894
(1939,-455,-100)
19.894
(1939,-455,1250)
19.894
(1980,-210,60)
57
(355,-215,-60)
1.479
(355,-495,-60)
1.974
(355,-215,1150)
1.479
(355,-495,1150)
1.974
(1970,170,-60)
1.479
(1970,-530,-60)
1.974
(1970,170,1150)
1.479
(1970,-530,1150)
1.974
(347,-194,-60)
3.375
(347,-194,1135)
3.375
(1966,165,-60)
3.375
(1966,165,-1135)
3.375

Is
seat belt
locked
yes
Is helmet
strapped
on
yes
Engine on
THE KRIEGER

no

Engine off

no

120
100
80
60
40
20
0
Mounting point
failure of engine
deformation of
Failure of RHO
gear oil leakage
drive shaft failure
Gear box star failure
Clutch failure
failure of chain drive
Failure of sprocket
Failure of
Improper
Oil seal has failed
Over heating of

Failure Modes vs. RPN

RPN
6.00
5.00
4.00
3.00
2.00
1.00
0.00

Corrected RPN

THE KRIEGER

Mounting point
failure of engine
deformation of
Failure of RHO
gear oil leakage
drive shaft failure
Gear box star
Clutch failure
failure of chain
Failure of sprocket
Failure of
Improper
Oil seal has failed
Over heating of

DFMEA

Failure Modes vs. Occurance

Occurance

Corrected Occurance

DESIGN VALIDATION PLAN

THE KRIEGER

PROJECT PLAN

The total cost of the vehicle is estimated to be Rs. 1,59,500.

THE KRIEGER

3-D VIEW

THANK YOU !!!

THE KRIEGER