Design Presentation ROA ROADIES DIES Regd. ID : 81341 National Institute of Foundry & Forge L/O/G/O Technology , Ranchi www.themegallery.com
TEAM ORGANIZATION TEAM CAPTAIN TEAM VICE-CAPTAIN RICHARD DOLEY AKSHAY TRIPATHI TECHNICAL MANAGEMENT UTSAV MAHTO KR. SAMBHAV Design & Publicity Sponsorship Procurement Fabrication Analysis VIKAS UTSAV ANUROOP, RISHIKANT CHAITANYA DWIVEDI RAJ VARDHAN RAJA,SATISH VISHAL PANDEY ANKIT GUPTA ABHIMANYU ASHUTOSH Tires & Roll Cage Steering Suspensions Brakes DHARMENDRA BITTU GUPTA HITESH GODWANI MANAS GOND RAJAT ROHIT UJJIR
ROLL CAGE Material Carbon Steel AISI 1018 DESIGN METHODOLOGY UTS 365 Mpa • Driver-oriented Cockpit design. Carbon content 0.18% • Light weight, Compact and simple. Outside dia.: 25.4 mm • High Roll stiffness and structural rigidity Wall thickness: 3.05 mm • Easy egress during mishap. • Least no. of welds and members WELD JOINTS Number of weld joints = 62 Weld length = 4.787 m
Roll Cage Analysis ( Software: ANSYS 13.0 ) Front Impact Analysis At Speed : 60 km/hr (16.67 m/s) Impact Time : 0.1 sec Thus, Load= 60000 N on front members. Max STRESS : 174 Mpa Max DISPLACEMENT : 2.38 mm Factor of Safety: UTS/S max = 365/174 = 2.1 Side Impact (Safe case of Side Roll over) Load: 2G loading (6180 N) on side members. Max STRESS : 69.4 Mpa Max DISPLACEMENT : 2.26 mm Factor of Safety : 365/69.4 = 5.25 Roll Over (Dynamic) Analysis Load: 2G Horizontal on side members 1G Vertical on top members . Max STRESS :136 Mpa Max DISPLACEMENT : 5.5 mm Factor of Safety : 2.68
Suspension : Double Wishbone Parallel SLA FRONT LOWER ARM Front Lower arm , centre SHOCK MOUNTING REAR UPPER ARM LOCATION : Upper arm, inner Rear LENGTH OF A ARMS : Upper arm 312 mm Front Lower arm 338 mm Rear Upper arm 263 mm Lower arm 287 mm ROLL CENTER HEIGHT: Front 81.66 mm Rear 114.82 mm
Steering • Rack and Pinion; simple design and easy to install. • 100% Ackermann geometry Target Specifications: Gear Ratio 12:1 Caster 5° Positive Camber (static) 2° Negative Toe-in 10 mm King-pin Inclination 12° Scrub Radius 44 mm Lock Angle 40° (approximately) No. of turns to steer from Extreme Left 2.66 turns to Extreme Right Turning Radius
Braking System Maruti 800 calipers and disc will be used Features: Hydraulic disc brakes Two independent braking circuit Equipped with SMART Turning Assistance System Two servo motor assisted valves on rear circuit. While turning left, on application of brakes will lock both the front wheels and rear left wheel. Rear right wheel with drive will get moment along these 3 locked wheel hence turning would be easier. Target Specs: Pedal Ratio 6.2:1 Braking Effort 1300 N per wheel Deceleration 7.53 m/s 2 Stopping distance 21.5m (max speed 60 km/h) Assumption: Brake Efficiency = 70% Coefficient of friction =0.65 ῖ = BfwR/r Bf = M ag s = v 2 / 2gaₓ/g Formula used
Power Train Briggs and Stratton Engine: 10 hp OHV Intake 20S332 0036 New engine with 3800rpm Overhead Valve Design (OHV) Runs cooler and cleaner delivering Torque* (ft-lbs, more power, longer engine life and 14.50 gross) improved fuel economy Engine Displacement (cc) 305 Number of Single Cylinders Flange Coupling Engine Horizontal Shaft Configuration Engine OHV Technology 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
Safety & Ergonomics Kill switches will be installed to kill the ignition in case of Racing type 3 ways Pivoted bumper with spring emergency Adjustable seats, for support in front driver comfort. of vehicle to absorb energy from collisions 5 point harness seat SAE grade brake lights belt system along with will be installed and all neck restraint and arm wiring will be properly restraint insulated and clipped. Belly pan running entire length of cockpit, Roll cage foam padding and All rotating parts will be body panels will be properly shielded with sheet provided metal. Splash shields and Drip pans will also be provided Fire extinguisher within Gear indicator to Belly pan and Roll the reach of driver will enable quick gear cage padding be provided shifts
Design Specifications Overall length 2.3 m Front: 1.55 m Track width Rear: 1.45 m Wheel base 1.60 m Overall weight 310 Kgs (inclusive of Driver) Engine Briggs and Stratton 10hp OHV Transmission Mahindra Alfa(modified) Tires 22 x 8 inches, 6 ply ATV Rims 10 x 6 inches SAE 1018 seamless steel tubes Roll Cage 1” OD and 3 mm wall thickness Double Wishbone suspension Suspension (front and rear) (Parallel and unequal arms) Customized Centered Rack and Pinion Steering System Gear Ratio = 12:1 Braking (front and rear) Hydraulic Disc brakes Maximum Torque 19 Nm @ 2900 rpm Maximum Speed 60 KMPH
2-D views
Final View
Design Validation Plan No Description Means Of Accomplishment Accomplishment Allotted Targets Resource 1. Welding test Strength of welded Abhimanyu Universal Testing machine components should be within Yadav permissible limits. Should not be less than the Ashutosh 10 inch Spacer. 2. Ground Clearance specified value i.e. 10 inch Saraswat Test The vehicle should stop within Ankit Gupta To be tested on track with 2 different observers 3. Braking Test for wheels on each side. Braking distance to be safe limits and all the wheels measured from point of brake application to should be locked point of stop. 4 Wheel Travel Should be at least 6-7 inches Raja Sah Ruler (jounce rebound) Driving the car in neutral steering position 5. Straight Line Stability Should move in a straight line Rohit Ujjir parallel to the white strips on road. when steering is at neutral position. 6. Turning Radius Should be approximately Anuroop Radius will be measured using measuring tape. equal to the calculated value. Kulshresta Vehicle should be tested in various roads 7. Fuel Leak Test Should not leak fuel or fluid at Vishal Pandey conditions and any case of spills to be any circumstances. scrutinsed. Obtained data shall confirm the calculated 8. Speed and By recording the time travel Hitesh Godwani value while traversing a path acceleration test
College & External Facilities MACHINING Center Lathe Universal Milling Machine Grinding Machine Drilling Machine WELDING Metal Inert Gas welding machine TIG welding machine Electric arc welding machine MANUFACTURING MACHINES CNC Milling Machine Hot Isostatic Press(HIP) Machine Rapid Prototyping Machine TESTING MACHINES Brinell Hardness testing machine(3000 kg) Universal tensile testing machine(60 tonne) EXTERNAL FACILITIES: CNC Pipe Bending. Laser Cutting (for hubs). Paint Equipment.
Project Plan
Cost Estimates Category Items Cost Steel tubes, Sheet Metal, Frame 37,200 Welding supplies, roll cage padding etc Engine, transmission, shifters, Power Train 47,000 chains, sprocket, couplings etc Rims & tires(4+2) Wheels and tires 39,900 Shocks, springs, A arms, uprights, Suspension 22,000 hubs, spindles Rack & pinion, steering column, Steering 11,600 steering arm, steering wheel, tie rods etc Driver’s suit, helmet, fire Safety equipments 37,500 extinguisher, harness system, restraints, kill switch etc Calipers, master cylinders, servo Braking 14,500 motors, brake lines etc Travel, transportation, Misc 30,000 accommodation etc Total 2,39,700
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