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Intell DynaMech Engineers Association

Team Captain:Faculty Advisor:

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Presents TeamFor Johnson Yesudas .AI D E AIntell Engineering CollegeD. Sreekanth M.TechR. David M.TechK. Ashraf Ali M.Tech

IDEA Performance Technology Optimized

IDEA Performance Technology OptimizedHome EngineeringJohnson Yesudas .A1

Friday, August 12, 2016EK-IDEA20152Provide a better atheistically designed go-kart and our technocrats merely make them seek livelihood, but to take our country ahead in all fronts of Automobile Innovations.

Promoting engineering temperament and competitive spirit among aspiring students through imparting knowledge of Automobile by designing, fabricating, optimizing & racing.

To fabricate the best optimized model with intial cost and enhancing our engineering knowledge with Elite karting 2k14 a real time strategy of go-kart.Vision:Mission of Team: Aim:Team Work can achieve any Dream Work

Aim:Vision:Mission of Team: Home EngineeringJohnson Yesudas .A2

Friday, August 12, 201633D View of the Vehicle with SpecificationEK-IDEA2015

3D View of Vehicle with specificationHome EngineeringJohnson Yesudas .A3

Friday, August 12, 20164Rule Book ConformationEK-IDEA2015ArticleSpecification / ContentConstraint Provided / RuleImplemented Values / Method RemarkA1.1 6.4Administrative RegulationEligibility, Age, Driver License & InsuranceLicense & Insurance available B 1.1 1.1.1With Four wheels & Capability Driver Height 190cms & weight 113kgsConfine as per rule B1.1.2 1.1.4Max vehicle Dimensions & Jack Pt Wi: 50,Le:80,Wheel base relationWheel Base: 43, Track width: R42.6,F34.4 B 1.1.5Steering SystemPositive Steering With Mechanical LinksPositive Steering without locking Wheels B 1.2.1-1.2.2On Road Capability Ground Clearance & Sharp EdgeClearance 2.5 & No sharp Edges B 1.3Vehicle Ergonomics Capacity95th %ile male & 5th %ile FemaleConfine as per rule & Avg ht of team is taken B 2.1- 2.1.16Engine Requirement Restrictions while Assembly & CautionConfine and Abide to rules B.3.1 3.5Electrical SystemBattery, Wiring, Lights & Kill SwitchSolar Power and confine as per rule B 5.1 5.9Cock Pit & Throttle ControlFirewall, Belly pan & Throttle consoleFire Extinguisher Fitted & Confine as per rule B 6.1 6.3.1Driver RestraintSeat Fastener, Shoulder Harness & LocationSingle Buckle fastener & Confine as per rule B7.1 7.4Braking system & Fuel TanksFoot brake lines and Fuel tank linesSafely Installed & Confine as per rule B8.1- 10.1.1Fastener, Guard and Driver EquipPreferred bolts, nuts & washer employedGuards, ISI Driver suit is used with Helmet

Home EngineeringJohnson Yesudas .A4

Friday, August 12, 20165Chassis DesignEK-IDEA2015Design Methodology: As per rule book confine & Considering the bare Weight of Kart, Engine & Racer. Material Selection : AISI 4130 (2 x 0.19 tube) with best rigidity often employed in FSAE vehicles.Calculation Results : Wheel Base 43, Track Width Rear 42.6 & Front 34.4 & Ground Clearance: 2.5

Material Property:E: 205KN/mm2, : 0.285,: 7850kg/mm3, t: 731N/mm2 y:460N/mm2, :42.7w/m0KStress Analysis Report: Max Stress : 370N/mm2Factor of Safety: 1.26Displacement: 2.61emm

Home EngineeringJohnson Yesudas .A5

Friday, August 12, 20166Ergonomics consideration in vehicleEK-IDEA2015

As per rule book confine & Considering the Average height of the team members.

As per rule book confine & Considering the Average height of the team MembersHome EngineeringJohnson Yesudas .A6

Friday, August 12, 2016Drawing of Disc BrakeBrakesEK-IDEA2015Design Methodology: As per rule book confine & Considering weight of the go-kart with driver.Selection: Disc brake with Double pistons acting towards on single Caliper & Pad is employed.S. NoConfigurationObtained ValuesSlipNo -Slip1.Brake ForceFFT= 352N & FRT= 653NFRT=725N2.Brake TorqueTRC= 60.2085 N-m3.Stopping Distance 20.27m13.54m4.Stopping Time4.49 sec2.99 sec5.Pedal Force98.1 N6.Leverage Ratio6 : 17.Pedal Efficiency80%8.Disc Dimensions0.24m x 0.006m (9.45 x 0.24)9.Caliper Dimensions0.025m x 0.075m

Drawing of Disc BrakeHome EngineeringJohnson Yesudas .A7

Friday, August 12, 20168SteeringEK-IDEA2015Design Methodology :As per rule book Confine & Considering Positive Steering without locking.Selection : Mechanical Linkages is employed for steering its simple with less effort & weight.S No Configuration Obtained values1.Wheel Base1066.8mm (43)2.Track Width 860mm (34)3.Track Rod482mm (19)4.Turning Radius1855mm ( 72)5.Ackermann Angle1506.Ackermann Arm Length238.1mm (9)7.Ackermann Percentage147%8.Steering Ratio1:19.Steering Wheel10 dia. wheel10.Steering effort87.7N

S NoParameterValues1.Kingpin inclination1002.Caster -120 3.Camber104.Toe out2mm

DHome EngineeringJohnson Yesudas .A8

Friday, August 12, 20169Drive TrainEK-IDEA2015Design Methodology : As per rule book confine & Considering provided engine specification data.Selection: Centrifugal Clutch is employed for better power transmission with low cost and weight.S. NoConfigurationObtained values1.Mass of Shoe0.36 kg2.Centrifugal force outwards1000.7 N3.Centrifugal force Inwards562.93 N4.Radial force of shoe437.45 N5.Friction force109.46 N6.Frictional Torque12.32 N-m (4.5 HP)8.Max Speed18.055m/s (65kmph)9.Transmission to Rear Axle1.6 H.P

Exploded View of Clutch

Exploded View of ClutchHome EngineeringJohnson Yesudas .A9

Gantt ChartFriday, August 12, 201610EK-IDEA2015

Design Validation Plan11Friday, August 12, 2016EK-IDEA2015S.NOSYSTEMTEST METHODINSPECTIONACCEPTANCE CRITERIARESULT1CHASSISTHEORITICALSOFTWARE RESULTSPASSEDPHYSICALAnalysisNO BENDS OR CRACKS DEVELOPEDPASSEDPHYSICALVISUALNO BENDS OR CRACKS DEVELOPEDTO BE PERFORMED2TYRESPHYSICALVISUALNO SKIDDING OF VEHICLETO BE PERFORMED3ENGINEPRACTICAL TESTVISUALNOT MORE THAN 70KMPHTO BE PERFORMEDPRACTICAL TESTVISUALNILTO BE PERFORMED4STEERING TESTPRACTICAL TESTVISUALMAXIMUM TEST WITHOUT SKIDDINGTO BE PERFORMEDPRACTICAL TESTVISUALEASY TURNING WITHOUT HITTING CONESTO BE PERFORMED5BRAKESPRACTICAL TESTVISUALBRAKING DISTANCE NOT MORE THAN 4mTO BE PERFORMEDTHEORITICAL TEST BY FORMULAEAVERAGE PEDAL FORCE A MAN CAN OCCUR 98.1N(5lbs)PASSED

Design Failure Mode and Effect AnalysisFriday, August 12, 201612EK-IDEA2015COMPONENTFUNCTIONPOTENTIAL FAILURE MODEPOTENTIAL EFFECTS SPOTENTIAL CAUSES ODR.P.N.ACTIONS TAKENSODR.P.NBRAKESRetards motionLeakage of fluid from brake lineVehicle will not stop on time6Sub-standard brake lines54120Replace the brake lines61318Cracks due to high pressure54160Replace the brake lines62336Cracks due to rough terrains4496Provide covering62336Failure of pushrodAll wheels will not lock simultaneously8Restriction to motion of pushrod36144Pushrod should have adequate D.O.F82464KNUCKLEStationery part which integrates brakes, steering, transmission and suspensionKnuckle dislocateSevere effects on brakes and steering7Selection of improper material44112Use of high grade material72228Improper press fit and size of bearing64168Soldering of Knuckle722287Small cross-section area of stub axle4384Maintain cross-sectional area72342Crushing7Free length of stub axle45140Maintain length72342Shear

EXHAUSTGuides exhaust gases awayCorrosion on inner surfaceUnpleasant or cracking sound7Inner surface at lower temperature than exhaust gases leading to condensation66252Replace exhaust72684Formation of acidic mixturePEDALLever which actuates A B C of the vehicleMovement of pedal constrainedPedal does not reciprocate back8Accumulation of mud near pedal72112Clean with high pressure jet of water84264Difficulty in braking and accelerationProvide a metal sheet covering83248FUEL LINESTransportation of fuelFuel line or component sealing failureChance of fire if fuel comes in contact with engine7Improper maintenance64168Proper sealing should be inspected74384Crack in linesFuel loss6Cracks due to vibration65180Lines should be mounted rigidly 64372Excess tightening of line screwImproper flow of fuel6Poor judgement while installation63126It should be adequately tightened64372SPARK PLUGIgnites fuel by means of electric sparkWet spark plugNo sufficient voltage to start the engine7Contact with water74196Cap should be provided to protect from water74256Low voltage6Excessive usage54120Distance between the electrodes should be checked to be around 0.8mm74256Carbon deposition7Incomplete combustion of fuel45140Spark plug should be cleaned with air jets75270BATTERYSupplies electric energyShort circuitStarter motor will not work8Contact with water63144Metal sheet covering for battery should be provided82232Discharge of batteryAll electrical connections may fail5Over usage54100Engine should be kept running51210Improper connections5Failure of battery5375Fuse box should be provided61212

InnovationFriday, August 12, 201613EK-IDEA2015Implementing Automatic lights Switching through LDRs (Daylight Sensor).Working out the best Aerodynamic design.Automatic turn lights actuated with the >70 Angle of front wheel.Solar panel is employed for the charging batteries.

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College FacilityFriday, August 12, 201614EK-IDEA2015Production LabLathe MachineShaping MachineSlotting MachineMilling MachineGrinding & Drilling MachineWorkshopCarpentryFittingSheet MetalHouse WiringBendingManufacturingFoundryBlack smithyARC WeldingBand SawEngg LaboratoryElectrical & Electronic Instrumentation & CAD/CAMThermal & Heat TransferMetrology & Material ScienceStrength of Material & Hydraulics

Arc Welding Turning Drilling Slotting Band Saw Milling ShapingMIG & TIG Welding Not Available

Home EngineeringJohnson Yesudas .A14

Team Structure and Allotted ResponsibilitiesFriday, August 12, 201615EK-IDEA2015S.NoName of the ParticipantsPrivilegesDesign TaskFabrication Task1Anthony Johnson Yesudas (Cpt)Work allocation & Follow upCAD, Chassis & DocumentationOptimization & Inspection2R. V. N. Anurag1 ( - Team)Alpha Team CaptainSteering Calculation & DVPSteering Assembly3Y. Maruthi2Asst & Manual DrawingDrawing with Exploded ViewBumper & Pads Arrangements4R. Rajesh Reddy3Assisting teamCross CheckingService & Maintenance5A. P. D. Salman Basha4 (Racer)Asst & Subject expertMaterial Selection & ValidatingStub & Rear Axle Assembly6U. Jagadesh1 ( - Team)Gamma Team CaptainBrakes, Drive Train & AerodynamicDisc Brake Assembly7R. Kusuma Reddy2Asst & Project PlanningGantt ChartBelly pan & Pedals Assembly8N.Yeswanth Sharma3Asst & Manual DrawingDrawing with Exploded ViewElectrical Mounting Arrangements9K. Nagasunkanna4Asst & Subject expertCross Checking & ValidatingDrive train Assembly & Welder10T. Subba Reddy1 (-Team)Beta Team CaptainMaterial Selection Criteria & DFMEATyre & Wheel Alignment11K. Ravi Kumar2Asst & Subject expertCollege facility infoTechnician & Engine Assembly12B. Basha3Assisting teamCross Checking & ValidatingTurner & Machinist13K. Venkat Subbaiah1 (-Team)Omega Team CaptainCost Report & ErgonomicsMaterial Procurement & Fitter14M. Varun Kumar2Assisting teamSpecification sheet & Market SurveySafety measures Arrangements15R. Prudvi Raj3Asst & SponcershipVendors quote & EstimationShipping & Transportation

Home EngineeringJohnson Yesudas .A15

Cost ReportFriday, August 12, 201616EK-IDEA2015S NOPart NameMaterialCost in Rs/-1Chassis & PlateAISI 413030502Wheels & TyresWhole Set195003Axle & HubsWhole Set60004Braking SystemDisc brake set30005TransmissionCentrifugal Clutch & Chain Sprocket20006Electrical SystemSolar Panel, Battery, Switches and Lights40007Mounting & BumperDash Board50008Manufacturing & LaborWelding cost, Machine cost & Labor Allowances 40009Material ShippingTransportations Cost200010MiscellaneousBelly pan, tie rod & fire extinguisher etc250011EngineBrigg Stanton Vanguards 6.5 HP15000Total Cost($1066)-66050

For your cherished time

17Friday, August 12, 2016EK-IDEA2015IDEA team will be an International Racing Marshalls in a Couple of years

Where do you see your team after two years?Home EngineeringJohnson Yesudas .A17

Queries18Friday, August 12, 2016EK-IDEA2015