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140728 saffrony institute of technology virtual baja2015_presentation
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- 2. RULEBOOK ABSTRACT 2 ParametersRulebook Value Our Value Length of ATV 108 inch 74.53 inch Width of ATV 64 inch 59 inch Helmet Clearance 6 inch 6.3 inch Material of Rollcage Material with 0.18 % C content ASTM-106 Grade-B with 0.19% C content Wheels Alignment 4 wheels must not be in same line Shoulder Clearance 3 inch 4 inch Rear Roll Hoop Inclination Max. 20o 15o Distance of LDB members from weld joints Max. 5 inch 2 inch Angle between FBM to vertical line Max 45o 43.17o Brakes The braking system must be segregated into atleast two independent hydraulic circuit
- 3. Car weight 300 Kg Max. speed 58.38 Km/hr Ground clearance 330 mm Turning radius 3.30 m Max. acceleration 6.13 m/s2 Stopping distance 8.29 m Stopping time 2.64 sec TECHNICAL SPECIFICATIONS 3 DesignTargets Roll cage Brakes • Brake circuit :Diagonal • Brake Diameter: 200 mm(F&R) • Stopping Distance(58 Km/hr.): 13m • Stopping time(58 Km/hr.): 1.60 sec Steering System • Type: Rack & Pinion • Steering Ratio: 16:1 • Wheel Base: 1600 mm Suspension • Type: Double wishbone • Spring: Concentric Springs • Deflection: 136 mm Power train • Height : 1250.0 mm • Length : 1893.3 mm • Width : 850.0 mm • Ground Clearance: 330 mm • Wheel Base: 1600 mm • Track width (mm) : 1500(R) & 1400(F) • Transmission System: Manual OEM • Maximum Speed: 58.38 Km/hr. • Maximum Acceleration: 6.13 m/s2 • Stiffness (N/mm) : 11.15(F) & 18.59(R) • Free length (mm) : 285(F) & 334(R) • Damping Ratio: 0.83(F) & 0.76 (R) • Deceleration :10.11 m/s 2 • Pedal ratio: 6:1 • Pedal force: 120N • Brake Force: 3221.72 N • Caster Angle: +8o(F) • Camber Angle: -2o(F) • Toe Angle: 0o(F) • Gradeability : 46.99% • Tractive force: 1963.15 N
- 4. 2D/3D VIEWS OFTHE ATV & ITS PARTS 4 Roll Cage A-Arms & Knuckles Springs Final ATV FINAL DESIGN FIRST DESIGN FRONT SIDE TOP FRONT REAR CONCENTRIC SPRINGS
- 5. ROLL CAGE ANALYSIS5 Frontal Impact 1) Load: 4g 2) Stress: 70 MPa 3) Deformation: 1.01 mm 4) F.O.S: 3.43 Rear Impact 1) Load: 4g 2) Stress: 80 MPa 3) Deformation: 2.14 mm 4) F.O.S: 3.0 Side Impact 1) Load: 1g 2) Stress: 110 MPa 3) Deformation: 2.86 mm 4) F.O.S: 2.20
- 6. 6 Torsion 1) Load: 1g 2)Stress: 76 MPa 3) Deformation: 0.76 mm 4) F.O.S: 3.15 Roll Over 1) Load: 1g 2) Stress: 52 MPa 3) Deformation: 0.30 mm 4) F.O.S: 4.63 Modal 1) Frequency: 41.97 Hz 2) Deformation: 14.1 mm Bump 1) Load: 1g 2) Stress: 170 MPa 3) Deformation: 5.33 mm 4) F.O.S: 1.4
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- 8. SUSPENSION 8 PARAMETER FRONTREAR Type of suspension Double Wishbone with unequal lengths Double Wishbone with unequal lengths Ground clearance 330 mm 300 mm Tyre size 635 mm outer dia. 635 mm outer dia. Max vertical wheel travel 177 mm up & 127 mm down 127 mm up & 100 mm down Suspension ratio 0.46:1 0.61:1 Anti-dive 13.43% - Anti-squat - 13.09% Camber -2 -2 Caster 8 NA Kingpin Inclination 12o NA Mech. Trail or Caster Trail 44.62 mm NA Scrub Radius 24.09 mm NA REAR FRONT Minimum F.O.S: 4.4
- 9. 9 FRONT REAR SUSPENSION(LAYOUT) Consideration PriorityReasons FRONT SUSPENSION Simplicity Essential This is a main goal of the team overall Light weight Essential Weight is the number one enemy of a race car, especially sprung weight 304 mm of Travel High Turning and stopping both require contact between the tyre and the ground, which is achieved through travel Durability High Withstand abusive-driving during the endurance race Shock Absorbing Desired Frontal impact cause a heavy amount of damage to the car Compatible with Steering REAR SUSPENSION Simplicity Essential Easier to fix, build, design, analyze Lightweight Essential Less weight is essential to be competitive 227 mm Travel High Allows tyre to be on the ground situations and still have traction Durability High Withstand abusive-driving during the endurance race
- 10. CONCENTRIC SPRING 10 ParametersFront Rear Inner Outer Inner Outer Wire diameter (mm) 6 8 6 9 Coil diameter (mm) 54 72 54 81 Active coils 22 14 29 17 Total coils 24 16 31 19 Load (N) 571.92 945.39 953.31 1575.82 Stiffness(N/mm) 4.20 6.95 11.58 7.01 Clearance between springs (mm) 3 6 Deflection of spring (mm) 136 136 Critical damping value(body) (Ns/m) 1776.17 2778.84 Critical damping value(wheels) (Ns/m) 2412.75 2492.78 Wheel rate (N/mm) 2528.68 7255 Critical damping force (Cr) (N) 1826.35 3095.81 Damping Ratio 0.83 0.79 Maximum Shear Stress: 457 MPa Deflection of Spring: 136 mm
- 11. STEERING 11 Track width: 1400 mm Wheelbase 1600mm Steering Ratio: 16:1 Scrub radius: 24.09 mm C-Factor: 33 mm Mechanical trail: 44.62 mm Turning Radius: 3.3 m (outer Front) Two Wheel Steering System layout STEERING SYSTEM : 2 Wheel steering System (OEM)
- 12. STEERING SYSTEM COMPONENTS 1) Steeringarms 2) Tie rods 3) Track rod 4) Rack and pinion 5) Steering wheel 12 TRUE ACKERMANN GEOMETRY Rif = )tan( 1 )tan( 1 l e 2sin ebl Formulas for 2 wheel steering system: 2sin ebl Rof = 2tan ebl Rir = e= Distance between two tie rods ends l= Wheel base b= Track width (F) ∅= Inner wheel lock angle ф= Outer wheel lock angle Rif= Radius (inner front) Rof= Radius (outer front) Rir= Radius (inner rear)
- 13. BRAKES 13 Front AxleLoad 808.5 N Rear Axle Load 1347.5 N Front Axle Load 1537.57 N Rear Axle Load 618.42 N STATIC LOAD DISTRIBUTION DYNAMIC LOAD DISTRIBUTION During Max .Acceleration 6.13 m/s2 Dynamic Front Axle Load 366.44 N Dynamic Rear Axle Load 1789.55 N Components • All 4 Disc combination used to achieve 4 Wheel Lock. • Disc Used –200 mm (OEM) • Master Cylinder Used – (OEM) Remarks • This particular combination of Calipers is chosen due to its Ease of Mounting Bleeding points on top. • Diagonal Braking Circuit Split used so that braking power is available on both Axles in case one Circuit Fails.
- 14. 14 BRAKE CIRCUIT Type of brakeused Disc Brake Front 200 mm Rear 200 mm Master Cylinder 1 tandem master cylinder Brake circuit Diagonal type Brake Force 3221.72 N Stopping distance (58 km/hr.) 13 m Deceleration 10.11 m/s2 Stopping time (58km/hr.) 1.60 sec. Pedal force 120 N Pedal ratio 6:1 • Total weight of vehicle is 300 kgs • Load on front axle is 37.5% • Load on rear axle is 62.5%
- 15. POWER TRAIN TYRES 15 Torque (ft-lbs, gross) 14.50 Engine Displacement (cc) 305 Numberof Cylinders Single Engine Configuration Horizontal Shaft Engine Technology OHV Length (in) 12.3 Width (in) 15.4 Height (in) 16.4 Weight (lbs) 50.4 Bore (in) 3.12 Stroke (in) 2.44 Engine Fuel Gasoline Spark Plug RC12YC MAX. TORQUE AT 2600 RPM ENGINE SPECIFICATION • Duro -Power Grip ATV Tyres • Dimension : 25x8-12 ; 6 Ply Rating • This tyre is radial constructed that designed to help alleviate the hard impact when riding riding on rough terrain with pits & gravel & boost driving comfort. • Innovative sidewall & ply structure aids in protecting the tyres from punctures , protect the rim & boosts the life of tyre
- 16. DESIGN METHODOLOGY OFTRANSMISSION 16 Quantity Gear 1st 2nd 3rd 4th Reverse Gear Ratio 31.48 18.7 11.4 7.35 55.08 Velocity(m/s) 3.8 6.41 10.52 16.31 2.07 Acceleration (m/s2) 6.13 3.63 2.21 1.42 10.70 Tractive force(N) 1963.15 1163.80 709.12 457.10 3425.51 Gear Box : 4 Forward and 1 Reverse (OEM) Transmission System: 2 Wheel Rear Drive ATV
- 17. COST & WEIGHTREPORT 17 Team Effort’s Cost Report OUR SPONSORS Total Weight: 300 Kg Total Cost of ATV: Rs. 2,32,000
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- 19. Design Parameter Potential failure mode(s) Potential cause(s) of failure Potentialeffect(s) of failure S O D RPN Preventive actions Roll Cage Bending and buckling Impact load High risk to driver 9 1 5 45 High factor of safety Axle shaft Bending and fracture Impact load and excess wheel travel Failure of Power train 6 2 3 36 Provide sufficient deflection and damping to suspensions A-arms Spring Knuckle Bending Static and Dynamic load Failure of Suspension and Steering System 5 1 4 20 High factor of safety Torsional Shear and/or Buckling 6 2 4 48 Use Concentric Springs 7 1 6 42 High Factor of SafetyDirect Shear and Bending Tie rod Bending of rod and/or fracture of ball-joint Front impact and excess wheel travel Failure of Steering System 5 2 2 20 Provide sufficient deflection and damping to suspensions Master Cylinder Loss of hydraulic fluid Leakage in hose Failure of Braking System 7 2 3 42 Use hose material with higher strength Testing part/Equipment Method Theoretical Value Actual Value Ground clearance Measurement by Steel Ruler 13 inch Stopping Distance Measurement by Measuring tape 11m Speed Using Stopwatch 58.8 Km/hr. Turning Radius Practically (Figure test; Measuring tape) 3.3m Steering Ratio Protractor 16:1 DFMEA DATA VALIDATION PLAN 19
- 20. MANUFACTURING PROCESS 20 Processeswhich Team is going to use for Fabrication Cutting Process Hacksaw Machine cutting Drilling Process Drilling Machine Turning Process Lathe Machine Bending Process Bending Press Welding Process Manual Metal Arc Welding Grinding Process Grinding Machine WORKSHOP FACILITIES
- 21. Chitralekha N. (Faculty Advisor) VyomMakani (Vice Captain) Power Train Parth S. Kevin C. Suspension Hanee Patel Aniket Patel Nikhil G. Brakes Sahil Bali Samay Patel Roll Cage Vyom Makani Pranav Mehta Steering System Nikhil G. Jay Vyas TEAM ORGANIZATION 21 Kamlesh S. (Faculty Advisor) Samay Patel(Captain) Roll cage Pathik Patel Aditya Dave Suspension Ruchik Raval Hanee Patel Steering System Jay Vyas Amit Dev Brakes Avnesh Rawat Bhavik Purohit Power Train Milind Kadiya Jay Joshi MARKETING Sunny Patel Utsav Shah Divyansh U. Utsav B. Samay Patel Design Team Fabrication & Logistics Team
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