BAJA SAEINDIA 2014 Team Abhedya Racing

BAJA SAEINDIA 2014 Team Abhedya Racing

• 1.
  BAJA SAEINDIA 2014 MARATHWADAMITRA MANDAL’S COLLEGE OF ENGINEERING, KARVENAGAR, PUNE, MAHARASHTRA.
• 2.
  SPECIFICATIONS, TARGETS AND3D VIEW 1 BAJA2014_TeamAbhedya_MMCOE_Pune Specifications : Targets For Designing BAJA 2014 Vehicle : Provide Maximum SAFETY to Driver. Keep Minimum Manufacturing Cost. Maintain 100 % COMPLIANCE with the Rule Book. Keep Weight as Minimum as Possible. Weight 280-290 kg. Maximum Dimensions 2410x1626x1465 mm3 Drive Rear Wheel Drive Engine 10 HP, 305 cc Suspension Double Wishbone & McPherson Strut Transmission Manual Transmission Braking 4 Wheel Disc Brakes Steering Rack and Pinion 3D View :
• 3.
  ROLL CAGE DESIGN Material AISI1018 Steel ( Syt= 365 MPa ) Diameter of Steel Tube 25.40 mm Thickness of Steel Tube 3 mm Maximum Length 2410 mm Maximum Width 915 mm Maximum Height 1194 mm Overall Weight 60-65 Kg BAJA 2014 Rule Book Material Selection Selection of Diameter and Thickness Driver Ergonomics Requirements of Other Subsystems Design Parameters : Specifications of Roll Cage : 2 BAJA2014_TeamAbhedya_MMCOE_Pune DUMMY COCKPIT ( Scale : 1:1 )
• 4.
  Force 35 kN G’s10g Max. Stress 233.17 MPa Max. Deformation 4.3 mm F.O.S. 1.57 Front Impact : FEA REPORT Force 18 kN G’s 5g Max. Stress 289.77 MPa Max. Deformation 7.42 mm F.O.S. 1.26 Side Impact : Force 9 kN G’s 2.5g Max. Stress 249.37 MPa Max. Deformation 9 mm F.O.S. 1.46 Roll Over : 3 BAJA2014_TeamAbhedya_MMCOE_Pune
• 5.
  TRANSMISSION SYSTEM Gear ActualCalculated 1st 31.47 32.55 2nd 18.70 - 3rd 11.41 - 4th 7.63 7.56 Reverse Gear 55.08 - Gear Ratios : Maximum Speed 59.59 Km/hr (16.55 mps) Maximum Acceleration 2.03 m/s² Wheel Torque 498.87 Nm % Gradeability 53.45% Traction 1571.27 N Calculations : • Engine Specifications : Briggs and Stratton (10 HP, OHV, 305cc) Gear Box Selected : Make Piaggio Ape Type Constant Mesh Shifting Sequential 5- Speed Gear Box 4 Forward & 1 Reverse 4 BAJA2014_TeamAbhedya_MMCOE_Pune ADAPTER
• 6.
  STEERING SYSTEM Camber (Static)-1° (Front) +1° (Rear) Caster 5° Steering Axis Inclination 8° Scrub Radius 96 mm Toe in 3 mm • Steering Selection : Front Wheel Steering • Steering Gear Mechanism: Ackermann Mechanism • Steering Gear Type: Rack and Pinion Specifications : Configuration : Steering Effort (Static) 40.01 N Lock to Lock Turns 3.2 Turning Radius 3.72 m Steering Ratio 15:1 Calculations : 5 BAJA2014_TeamAbhedya_MMCOE_Pune
• 7.
  Front Double Wishbone (Short-LongArm and Parallel) with Coil Spring and Damper Rear McPherson Strut a. Maintain undamped natural frequency from 1 Hz-3 Hz. b. To keep rear suspension 30% stiffer than the front. c. Minimize chassis roll by maintaining roll gradient in a range of 1-1.8°/g (of acceleration) SUSPENSION SYSTEM Suspension System Employed : Design Target : 6 BAJA2014_TeamAbhedya_MMCOE_Pune FEA Report of Wishbone : Force 4687 N Max. Stress 138.05 MPa Max. Deformation 0.40 mm F.O.S. 2.64 Sprung 300 kg. Unsprung 80 kg. Max. Mass:
• 8.
  Parameter Front Rear Loadon Each Spring (P) (Considering 2g) 1177.20 N 1765.80 N Spring Index (C) 9 10 Mean Coil Diameter (D) 81 mm 90 mm Wire Diameter (d) 9 mm 9 mm Active Turns (N) 10 6 Free Length (L) 212.33 mm 194.73 mm Deflection (δ) 93.33 mm 115.73 mm Spring Stiffness (K) 12.61 N/mm 15.25 N/mm Torsional Shear Stress (τ) 387.03 N/mm² 635.07 N/mm² Permissible Shear Stress (τ) 650 N/mm² 650 N/mm² SPRING DESIGN 7 BAJA2014_TeamAbhedya_MMCOE_Pune Parameter Front Rear Wheel Rate (Kw) 13.92 N/mm 20.55 N/mm Roll Stiffness (Kø) 470.71 Nm/ °roll 474 Nm/ °roll Roll Gradient 1.16 °/g ( where g is lateral acceleration) Suspension Geometry In Roll :
• 9.
  BRAKING SYSTEM Deceleration 5.21m/s² PedalForce 50 N Stopping Distance 15 m Total Braking Torque Required 773.96 Nm Torque Achieved 1105 Nm Diagonal Split Braking Circuit TMC with 19 mm Diameter All Four Disc Brakes with Effective Radius 102 mm Double Pot Caliper with 20 mm Diameter Dimension of Front Tyre : 23x7-10 inch Dimension of Rear Tyre : 25x8-12 inch Velocity (v) 12.5 m/s Weight of the Vehicle (m) 380-400 kg Coefficient of Friction (µ) 0.65 Disc Diameter (D) 0.23 m Pressure Applied on Disc (P) 15.53 bar Area of Piston (A) 6.28 x10-4 m² Friction Radius (Rf) 0.102 m Calculations : Specifications : Parameters & Assumptions : Brake Layout Circuit : 8 BAJA2014_TeamAbhedya_MMCOE_Pune
• 10.
  THERMOELECTRIC GENERATOR Objective WasteHeat Recovery Working Principle Seebeck Effect Advantages 1. Weight Reduction upto 13 kg. 2. Battery Charging Specifications : Mechanical Electrical Dimensions 3x3x0.5 in3 Power Output 15W x 4= 60W Weight 15g x 4 = 60g Voltage 12 V Material Lead Telluride Current 5 A Environmental Maximum Hot Side Temperature 325 ̊C Maximum Cold Side Temperature 30 ̊C Temperature Difference 260 -295 ̊ C (for Max. Power Output) 9 BAJA2014_TeamAbhedya_MMCOE_Pune
• 11.
  10 BAJA2014_TeamAbhedya_MMCOE_Pune AN INNOVATIVE STEPTOWARDS SAFETY Product BETA FOAM 87100- 87124 (Rigid Polyurethane Foam) Application Increase Stiffness and Crashworthiness of Automotive Bodies. Tube Without Foam : Tube With Foam : Peak Load : 32869.2 N Peak Load : 38710 N
• 12.
  Department Material Test Load (N) Max. Equivalent Stress (MPa) Remarks CalculatedApplied Roll Cage AISI 1018 ( Syt = 365 MPa) Front Impact 34353.86 35000 233.17 Safe Side Impact 17176.93 18000 289.77 Safe Roll Over 8588.46 9000 249.37 Safe Department Component Braking Torque (Nm) Remark Required A Braking Calipers and Disc Assembly 773.96 1105 Safe Department Components Parameters Remark Transmission Piaggio Ape Gear-box & Drive Shaft Gear Ratio Drive Shaft (mm) Safe Calculation Actual Calculation Actual 32.55 31.46 13-15 20mm 7.56 7.63 DESIGN VALIDATION PLAN 11 BAJA2014_TeamAbhedya_MMCOE_Pune
• 13.
  DESIGN FAILURE MODEEFFECT ANALYSIS 12BAJA2014_TeamAbhedya_MMCOE_Pune COMPONENT FAILURE MODE FAILURE EFFECTS S O D R P N ANALYSIS AND REMEDIES Drive Shaft Due to Torsional Shear Seizure of Vehicle 7 2 3 42 Use Drive Shaft of Gear Box Having Diameter Equal or Greater than Required / Calculated. Due to Extreme Angular Displacement Risk of Accident at High Speed 7 4 3 84 Use a Suspension System at Rear which Provides Limited Vertical Wheel Movement. Tie Rod Due to Impact Crushing 7 3 2 42 Install Bumper at Vehicle Front. Lack of Lubrication Improper Handling Proper Lubrication. Wishbone Arms In Bending Vehicle Seizure Severe crash 9 5 2 90 Use Material of Higher Bending Strength and Stiffness. Also Design Arms Considering Worst Case Scenario. Brake Tandem Master Cylinder Leakage from TMC Possible collision 8 2 3 48 Use of 2 TMC of Diagonal Split System. Brake fluid lines Mechanical Damage due to Improper Installation 6 4 2 48 Install Brake Fluid Lines along the Roll Cage with Snaps. Roll Cage Welding Failure Complete Seizure of Vehicle and Subsystems 6 5 2 60 Maintain Good Weld Quality . Design Roll Cage Structure for Higher Dynamic Loads. Front And Rear Knuckles In Extreme Bumps, Droops and Free Fall. Breakdown and Crash. 7 5 2 70 Use Standard OEM Knuckles to Avoid Damage.
• 14.
  PROCESS PLAN 13 BAJA2014_TeamAbhedya_MMCOE_Pune
• 15.
  COMPONENT COST (₹) RollCage Pipes and Related Equipment 18,545 Tyres 41,768 Steering 11,600 Suspension System 8,400 Transmission 33,070 Braking System 36,280 Electrical, Battery And TEG 28,732 Safety Equipment 46,622 Painting 3,000 Other 20,000 Total Cost of Materials 2,48,017 Total Estimated Cost of the ATV = Material Cost +Engine Cost +Labour Cost +Transportation Cost = 2,48,017+35,000+15,000 + 60,000 = ₹ 3,58,017/- COST REPORT AND WORKSHOP FACILITIES 14 BAJA2014_TeamAbhedya_MMCOE_Pune Metal Inert Gas Welding Bending Machine Geared Head Lathe Machine Universal Radial Drilling Machine Universal Gear Head Milling Machine Chop Saw, Power Hack saw Electric Arc Welding Machine Spot Welding Machine Bench Grinder, Hand Grinder WORKSHOP FACILITIES :
• 16.
  BAJA2014_TeamAbhedya_MMCOE_Pune THANK YOU… OUR SPONSOR: MARATHWADAMITRA MANDAL’S COLLEGE OF ENGINEERING, KARVENAGAR, PUNE Amount ₹ 1,75,000/-