TEAM ASTRA PRELIMINARY DESIGN REPORT

Nisar Ahamed N
Team Captain

ABSTRACT
This design report focusses on explaining the design and engineering aspects considered for building an ATV for BAJA SAEINDIA 2013. This report clearly explains all the assumptions and calculations made in the designing each system of the ATV.

model was created from the ground sketch keeping in mind the function and form. Before finalizing the model a full scale mockup (space frame) was made using bamboo sticks in order to ensure the space availability for all the systems in the vehicle. Much importance was given to the human ergonomics and safety. And to ensure this, a simple design which could be easily manufactured and also safe was finalized. The design was made for 100% compliance to the rule book.

INTRODUCTION
BAJA SAEINDIA is a collegiate design competition sponsored by the society of automotive engineers (SAE) that attracts engineering student teams from all over India. Each teams goal is to design, build, test, promote, and race a prototype of a single seat off-road vehicle hypothetically intended for production and eventual sale to the weekend offroad enthusiast. Team Astra comprises of 21 highly enthusiastic and determined young engineers handpicked from the Department of Mechanical Engineering, Sri Muthukumaran Institute of Technology. The teams main objective is to ensure that our ATV will be capable of completing all the task required to win this event and also be a potential vehicle to be sold in the market.

ROLLCAGE DESIGN
Design methodology
Fig 1. Ground sketch

Being a first time participant, the team followed a simpler and a basic design approach which comprised of the following i. Field Study ii. Initial Design iii. Space Frame iv. Analysis v. Design Finalization Starting with a brief field study, the initial ground sketch was made considering the boundary conditions specified. A full 3D
Fig 2. Initial 3D model

Space frame The exact initial model as created using CAD software was reproduced in the real time using bamboo sticks to ensure the ergonomic and spatial requirements of the vehicle.

Fig 5. Final 3D model

This model was made in the view to perform finite element analysis and testing using software.This model was subjected to various loading patterns inorder to study the feasibility of the design.

Fig 3. Bamboo model (space frame)

Fig 4. Bamboo model (space frame)

This space frame gave a clear view of the aspects that needed to be changed for satisfying the rule book and the other requirements. These changes were reflected in the CAD model and was analysed. Final Model The final rollcage was created using Pro Engineer 5.0 with stringent complaince with the rule book. Stress distribution was given primary importance when this model was designed. A light weight vehicle with no compromise to safety was considered. Analyis Finite element analysis was carried out on the model using NX Nastran 7.5. A 3D tetrahedral mesh was generated to a suitable element size and the anaysis was carried out. Properties of 1018 steel was taken as reference for the analysis. The yield strength of the material is 365Mpa.
Fig 6. Standard views of 3D model

The following loading conditions were applied and the results were studied. i. Frontal Impact Loading ii. Roll Over Loading iii. Static Loading Frontal Impact Loading In this type, assuming our vehicle collides head on travelling at a speed of 60kmph onto a similar vehicle of weight 300kg at rest. To achieve this, the rear part of the chassis was constrained and a force of about 25KN was applied to the front of the chassis. The deformation produced was minimal and the von mises stress fell below the accepeted criteria proving the chassis would be able to withstand crash.

The test yielded a minimum deformation of 7mm and a von mises stress falling well below the allowable stress.This verified the chassis to be a safe one for rollover condition.

Fig 8. Roll over condition

Static Loading In static analysis under self-weight, all the loads including the human and the primary systems of the vehicle was acted on the appropriate points and the suspension points were constrained.

Fig 7. Frontal impact condition

Roll Over Loading In this type, a force of 3KN was applied to the top edge of the chassis corresponding to the total weight of the vehicle. The base of the chassis was completely constrained for this loading condition.
Fig 9. Static loading condition

This analysis also yielded a minimum deformation and the von mises stress was well within then allowable limit.

Major considerations were given to ground clearance and travel while designing the A-Arms. The 3D model was created using PRO/E and it was analyzed in NX NASTRAN 7.5.

Fig 10. Static loading condition Fig 12. Front wishbone 2D sketch

The values of all the above analysis are tabulated below.

Analysis Type Results

Front Impact
200Mpa

Roll Over

Static Loads
94Mpa

Rod ends are to be used for mounting the arms onto the chassis. This has been selected because of its various advantages including an easily adjustable camber and castor.

Max. Stress induced (von - mises) Max Deformation Factor of safety achieved

73Mpa

7mm

7mm

1.5mm

5.3

4.1

Various other loading conditions like side impact, torsion test, bump test were also conducted which yielded similar results proving the all-round capability of the vehicle.

SUSPENSION
Fig 13. Rear suspension layout

Double wishbone independent type suspension are to be used. This was selected because of its simple arrangement and also provides a greater suspension travel. Suitable OEM spring damper system is planned to be used.

Fig 14. Rear wishbone 2D sketch Fig 11. Front suspension layout

For analysis, 3D tetrahedral mesh was performed on the arms for a suitable element size. The ends of the arms were 4

constrained and a force equaling 1/4th of the total weight of the vehicle was applied at the point of spring mounting.

This brake force distribution helps in better handling while sudden brakes are applied and also plays a major role during failure of brakes.

Fig 18. Schematic representation of diagonal brake distribution Fig 15. 3D model of wishbone

POWER TRAIN
The analysis yielded a deformation of 2mm and maximum stress of 57Mpa which is well within the allowable limit. The differential gearbox is a 4 forward 1 reverse type from a Mahindra champion alfa. It will be directly coupled onto the final driveshaft. This can be done by the help of CV joints and universal couplings. The gear box for this arrangement would be a synchro-mesh type.

SAFETY AND ACCESSORIES

A front bumper will been provided for ensuring less damage during crash. Fire extinguisher would be placed as per the requirements in the rule book. In addition, the open roll cage members will be foam padded and also a 5point restraint harness will be used along with arm and neck restraint for the driver. All the electrical requirements such as kill switches, tail lamps etc. will be provided as per the guidelines specified in the rulebook.

Fig 16. Analysis of wishbone

ERGONOMICS
Human ergonomic analysis was carried out in the vehicle. This analysis showed us the human reach around the vehicle guiding us in the placement of the steering and the dashboard. In addition, our design had separate consideration for ergonomics and it is clearly seen in the wide and spacious cockpit in the vehicle. The design is suitable for any sized human as we are using an adjustable steering and seats.
Fig 17. Suspension assembly

STEERING
Suitable Rack and pinion steering arrangement is planned to be used. This type of steering was selected because of its simple working mechanism which provides an easy and better maneuverability.

BRAKES
Independent hydraulic braking system is planned to be used with an OEM disc and caliper setup. A diagonal distribution of brake forces have been planned.
Fig 19. Reach Envelope

FINAL 3D MODEL

Fig 20. Isometric view

Fig 22. Front view

Fig 21. Side view

Fig 23. Back view

Fig 24. Rendered Model

EXPECTED SPECIFICATIONS
WHEEL BASE: 1880mm WHEEL TRACK: Front: 1448mm Rear: 1473mm HEIGHT: 1290mm WEIGHT (APPROX.): 300kg GROUND CLEARANCE: 254mm

CONCLUSION
Thus this report provides a clear insight involved in the design and analysis of our vehicle. All the values provided in the report are approximated to the least extent possible. The report is prepared keeping in mind that there may be few changes to the design at a later stage of the competition.

CONTACT
Nisar Ahamed N Team Captain +91 9840028612 nisar2612@gmail.com Mr. Ajay John Paul Faculty Advisor +91 98400 48821 ajayjohnpaul@gmail.com