Virtual BAJA 2015_(16190)_(Team Prayog)_PRESENTATION

Embed Size (px)

Text of Virtual BAJA 2015_(16190)_(Team Prayog)_PRESENTATION

Slide 1

BEANT COLLEGE OF ENGINEERING & TECHNOLOGY, GURDASPUR (GOVT.) (An Academic Autonomous and NBA Accredited Institute ) TEAM ID : 16190

SPECIFICATIONVALUESOverall Length2447.20mmOverall width1828.80mmFront track width1470 mmRear track width1550 mmWheel base1850 mmGround clearance 297 mmWheels- Front & rear 22127 & 221210 Maximum speed55.6 km/hrMaximum acceleration7.4 m/sGradabilty % 86.5 %Stopping distance19.4 m (40 km/hr)Kerb weight 190 kgRatio FAW & RAW 45:55

OVERALL VEHICLE DETAILS

ROLL CAGE

Materials AISI 1018AISI 4130AISI 1020Availability 432Strength 344Cost 423Weight 344Total141313

Material usedAISI 1018Yield strength 365 MPaTensile strength440 MPaElongation15%Outer diameter25.4 mmWall thickness 3 mmOver all length 2083.6 mmMax. width 718 mmWeight 54 Kg

Material selection

Ergonomics Related to Cockpit : Cockpit is designed in such a way that driver can exit within 5 seconds in an emergency . RRH is given an angle of 15 deg. To give a good sitting posture to the driver. Front bracing members are adjusted in a such way to give a wider view of vision. Side impact members are designed to protect the driver from external threats.Carbon 0.18 %Iron98.8 %Manganese0.6 %Sulphur0.05 %

Chemical Composition :Welding used for the manufacturing of the roll cage is MIG welding . Due to its lesser cost and good strength .

ANALYSIS OF ROLL CAGE

Front impact force - 24000 N (8.6G ) Max. stress - 184 MPa Deformation - 3.227 mm Factor of safety 1.98 Rear impact force - 24000 N (8.6G) Max stress - 293 MPa Deformation 3.06 mm Factor of safety - 1.24Roll over force - 2774 N (1G )Max stress 157 MPa Deformation 6.4 mmFactor of safety - 2.32Side impact force - 11928.2 N (4.3G) Max stress - 302 MPaDeformation 3.9 mm Factor of safety - 1.21

ParameterCase I Case IICase III Size of Mesh (Units) 20108 No. Of nodes 219584434629485534No. of Elements133446 236481253079Max value of Von-Misses Stress (MPa) 225.62 285.89290Percentage Error 52.2729.31 1.8

So we have selected the mesh size = 8 Because its Percentage error is less than 5 % after performing iteration .

SUSPENSION DESIGNType of Suspension (Front And Rear) - INWARD CONVERGING TRANSVERSE DOUBLE WISHBONE

CHARACTERSTICSFRONTREARGROUND CLEARANCE (m).297.315ROLL CENTER HEIGHT (m).231.281CAMBER (deg)-1.21-1.50CASTER (deg)3.183.18KPI (deg)12.533.18MOTION RATIO.8.9WHEEL RATE (N/mm)9.64515.612SPRING STIFFNESS (N/mm)15.0719.274NATURAL FREQUENCY (Hz)2.412.46RIDE FREQUENCY (Hz) 1.962.27ROLL STIFFNESS(Nm/deg)202.54327.15

CG Height (m) 0.505 Scrub Radius (m)- 0.067 Sprung mass (kg) 204 Unsprung mass (kg)- 76

Material Used 4130MAX . VON MISES STRESS-175MpaFOS-2.62Material Used- 4130MAX. VON MISES STRESS- 148MpaFOS- 3.1Bump travel (front)- 7inchBump travel (rear)- 6inchDroop travel (front)- 5inchDroop travel (rear)- 4inch

BRAKES Disc Brakes X-split brake circuit with master cylinder of Maruti 800 Bosch tandem cylinder (OEM) having bore diameter Inch and piston area of 0.4393 sq. Inch. Discs of Maruti Zen is used for front wheels and TVS Apache RTR 180 is used for rear wheels and calliper of respective discs are used. For Brake fluid DOT 3 is taken.SPECIFICATIONSVALUEFRONT DISC DIAMETER182mmREAR DISC DIAMETER270mmFRONT CALLIPER PISTON50mmREAR CALLIPER PISTON32mmBRAKE FORCE2058NPEDAL FORCE70lbsDECELERATION7.35m/sPEDAL RATIO6:1FRONT BRAKING TORQUE189.04NmREAR BRAKING TORQUE280.36NmCALLIPER PAD FRICTION COEFFICIENT(FRONT WHEEL)0.08CALLIPER PAD FRICTION COEFFICIENT(REAR WHEEL)0.29

SPECIFICATIONSVALUEFRONT CLAMPING FORCE12.86KNREAR CLAMPING FORCE3.548KNCYLINDER PRESSURE6.59MPaMEAN BRAKING RADIUS91.85mmWEIGHT TRANSFER552.814NSTOPPING DISTANCE19.4m(40km/hr)STOPPING TIME1.75s(40km/hr)

STEERINGSTEERING SYSTEMOver steerAckerman % - 80

Steering angle - inside - 40.51 (deg.) outside - 26.98 (deg.)Turning circle radius 2901.2mm

STEERING GEAR R & P RHD (MARUTI SUZUKI 800)Rack travel 120mmTurns lock to lock, rev. 3.25Steering ratio 12:1OBJ center distance - 110mLength of Tie rod 397mmLength of steer arm 86.9 mmSTEERING COLUMN CollapsibleWithout power assist

LOTUS STEERING ANALYSIS

Steer Toe Ackerman Turning circle Travel angle (%) radius (mm) {SAE} (mm) (deg.) 45.00 38.00 81.70 2979.55 30.00 22.70 71.53 4955.39 15.00 10.57 67.35 10418.21 0.000 66.16 0-15.00 -9.62 67.35 10418.21-30.00 -18.63 71.53 4955.39-45.00 -27.25 81.70 2979.55

STEERING WHEELSteering wheel diameter -390mmSteering wheel torque 58.5Nm

Wheel Geometry

POWER TRAINENGINE SPECIFICATIONSBriggs and Stratton305CC 10HP19Nm at 2800 rpm

Overall gear ratiosTractive force (N-m)Maximum velocity km/hrMaximum acceleration m/(sec) Gradability %age37.5:122949.47.486.525:1152913.54.757.612.5:1764.628.22.028.86.25:138255.60.614.4

TCVT= 14.5 lb-ft * (12 in/ 1 ft) * (3/1) * 0.83 = 433 in-lb =48.9Nm Factor of safety for shaft is 5.05 For tire diameter =22inch the maximum velocity attained by vehicle is 55.6 km/hr N= Transmission efficiency = 0.85 Torque on the wheel=420ft-lb = 569.4Nm 12.5:1 Gearbox is used TRANSMISSION : CVT COUPLED WITH MAHINDRA ALPHA GEAR BOX LAYOUT OF ENGINE , CVT AND GEAR BOX

COST ANALYSIS & WEIGHT DISTRIBUTION

PROJECT PLANNING

PartFunctionFailure ModelsPrecautionValidationAccomplishmentRoll CageBasic Soul Of Vehicle And To Protect The DriverWhen Material Reaches To Ultimate Stress Value.Use Of AISI 1018 Steel Having Yield Strength Value Equal 370 Mpa.Welding TestUniversal Testing MachineENGINETo Generate PowerSpark Plug Failure/Improper Functioning Of Old Filters.Regular Check Of Spark Plug & Filter Change.Fuel Leak TestVehicle Should Be Tested In Various Road ConditionTRANSMIS-SIONTo Transmit Power From Engine To WheelsImproper Lubrication/Unexpected Load.Use Of ISO Grade Oils .Speed And Acceleration TestRoad TestSUSPENSIONTo Absorbs Shocks And To Give A Smooth DriveWhen Coil Reaches To Solid Length.Proper Calculation And Assumption In Designing.Wheel TravelInch TapeBRAKESTo Reduce The Speed When Required And Emergency StopCircuit Failure Due To Leakage Worn Out Break Pads.Bleeding Of Vehicles Break Before Every Run, Checking And Replacement.Breaking TestRoad TestWHEELSTo Provide Good TractionInappropriate Air Pressure/Puncture Tire.Checking Of Air Pressure At Every Refuel Backup Extra.Tire Air PressureAir Pressure Gauge

DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN

11

TEAM COMPOSITION & COLLEGE FACILITIES TEAM STRATEGY FACULTY ADVISOR : SANDEEP GANDOTRA DEPARTMENTSTEAM MEMBERS ROLL CAGEARSHDEEP SINGH, AMAN RANA,VINAY KUMAR (Captain) ,LOVY MINHAS, SAEED AKHTAR, SACHIN, SATNAM SINGHTRANSMISSION ANUJ BHARDWAJ, SHIVAM BHARDWAJ,AMARJEET GULERIA, NAVJEET SINGH, KASHISH MAHAJAN, RAKESH ,SHAMSHER SINGH,VARUN SHARMA SUSPENSIONANSHUL SHARMA, ABHISHEK THAKUR, VINAY KUMAR, ANUBHAV MAHESHWARI, ABHINAV KUMAR, NITISH PANDEY, SATISHBRAKING GAGANDEEP SINGH, ANUJ BHARDWAJ STEERINGAMAN RANA, ARSHDEEP SINGH, AMARJEET GULERIADRAFTING & ANALYSIS KRISHNA KHOSLA,JATIN SARINE MANAGEMENTANUBHAV MAHESHWARI,SHAMSHER SINGH,UTKARSH

COLLEGE FACILITIES

For Roll Cage , Each and every equipment available in welding shop.

For Custom Knuckle , requirements are available in Carpentry , Foundry and machine shop.

For Seat Installation and Sheet Covering of vehicle , equipments are available in welding and sheet metal shop.

For clamping of Wishbones , each and every requirements are available in Central Workshop.

For Assembly and Installation of all other parts of vehicle, requirements are available in Central Workshop.