CRIMSON THRUSTERS Team ID: 14042 Anand Institute of Higher Technology

Presentation by : Gowri Shanker.K Hariharan.B Rahul Dharmarajan Srinivasan E.R

Design Methodology & Specifications

SI.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. RULEBOOK SPECIFICATIONS Length, Width 3D space around driver SIM placement Drivers head clearance from seat base Bend radius of the roll cage member Fasteners Minimum pipe thickness Minimum outside diameter of pipe Clearance between RRH and seat Weight(with driver) (kg) Wheel base MAX VALUES 108, 64 6 8 to 14 from the seat. 41 6 to 28 Bolts: Metric or Military Primary: 0.120 Secondary: 0.035 Primary: 1 Secondary: 1 3 CRIMSON THRUSTERS 80,62 7 10 45 10.5 Metric 8.8 0.12

Market Survey

Data Assumption

Design Calculation

OEM Comprison & Selection

Virtual Design
1 4 420kg 58

Analysis & Design Validation

FEA

12.
13. 14

Maximum speed
Ground Clearance Tyre dimensions

60kmph
-

54.5kmph
12.5 25x8x12

Completion

Roll Cage
All the members of the roll cage are made of SAE 4130 steel with OD 1 and wall thickness of .118 (3mm).

PROPERTIES OF MATERIAL:
Material :SAE 4130 Yield strength :600 N/mm2 Carbon composition :0.3%C(>0.18%C) The total weight of the roll cage is estimated to be 62kg. Total number of weld joints is 56 Maximum number of welds at a point is 2

The driver ergonomics for roll cage

Elbows to side impact member= 3.5 Drivers seat to fire wall(RRH)= 3 Drivers head to front bracing member= 15 Drivers helmet to top of the vehicle= 7 Overall roll cage length = 80 Wheel base = 59 Overall roll cage width = 42 Overall roll cage height = 54 Overall width = 58

Roll Cage
TEST DETAILS
Max Stress(N/mm2)

RESULTS
224.332

STRESS ANALYSIS

DISPLACEMENT

FRONT Load Applied(N) 20,000 IMPACT TEST Max Deflection(mm) 1.50883 FOS Max Stress(N/mm2) 2.7 296.421

REAR Load Applied(N) 20,000 IMPACT TEST Max Deflection(mm) 1.359

FOS 2.1

Max Stress(N/mm2)

284.399

SIDE Load Applied(N) 13,000 IMPACT TEST Max Deflection(mm) 4.967 FOS 2.2

Roll Cage
TEST DETAILS Max Stress(N/mm2) Load Applied(N) Max Deflection(mm) FOS BUMP TEST Max Stress(N/mm2) Load Applied(N) Max Deflection(mm) FOS RESULTS 328.304 9,000 15.2842 2 313.525 5,000 12.2493 2 STRESS ANALYSIS DISPLACEMENT

ROLL TEST

100 % Ackermanns steering Proposed track width = 54 Proposed wheel base = 58 Type of steering : Rack and pinion Maximum Angular travel of steering wheel : 540o Tie rod length = 9.889 Steering effort = 20 N

Parameter
i o Steering ratio Turning radius

Crimson Thrusters
37o 26o 15 : 1 3.133 m

Maruti 800
37o 32o 17 :1 4.4 m

Steering set up Adams car

Scrub radius Vs Steering angle

Brakes and Steering

Brake System Parameters
Type of Brake Pedal Ratio Diameter of Master Cylinder Caliper Piston Effective Diameter Rotor Effective Diameter Braking Force Stopping Distance Deceleration

Steering Geometry Santro

Disc Brake
4:1
22.25mm 43mm 230mm 3257.399 N 14.5 m

Target
Disc Brake 4:1 19.05 42mm 230mm 3296.16 N 14.33m 0.8g

Omni
Disc Brake
4:1
19.05mm 42mm 230mm 4239.38 N 11.145 m

Caster Camber Steering angle inner wheel

7o 1o 37o

Steering angle outer wheel

Turning Radius

26o
3.133m

0.925g

1.028g

OEM Selected: Maruthi OMNIs Braking System Weight Transferred: 208.43N Dynamic load acting on front during braking: 2848.45 N Dynamic load acting on rear during braking: 1271.74 N

Parameters Type Wire diameter Mean coil diameter Number of coils

Front suspension Unequal , parallel double wishbone 9mm 57 mm 11

Rear suspension Mac Pherson Strut 9mm 97 mm 5 4 12 mm

Total length Lower wishbone or control arm length

Upper wishbone length Inclination of wishbone wrt ground Caster angle Camber Scrub radius Spring stiffness Motion ratio Spring travel

322.63mm 231.71mm
208.8396mm 13.281o

540 mm 58.55mm
1.413o

7o +1o 5mm 9 N/mm 2.4 62.5 mm

0o +1o 5 mm 9.8 N/mm 2.61 57.4 mm

Camber Vs wheel travel

Toe angle Vs wheel travel

Scrub radius Vs wheel travel

Drive Train
The power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way Gear Final Gear Ratio 31.48 18.70 11.40 7.35 55.08 Max Vehicle Speed (Kmph) 12.7 21.4 35.11 54.45 7.27 Max Tractive Effort (N) 2119.32 1258.94 767.48 494.82 3708.14 Final Gear Ratio 55.08 32.72 19.95 13.40 31.48 Max Vehicle Speed (Kmph) 7.27 12.23 20.06 29.87 12.71 Max Tractive Effort (N) 3708.14 2202.80 1343.09 902.13 2119.32 Stub axle Engine working range (M) = 1750rpm3800rpm Recommended maximum power (PM) = 6.7 KW at 3800rpm To calculate power performance function Pe = P1 e + P2 e2- P3 e3 P1 = PM/ M P1 = 16.8455 /s P2 = PM/ M2 P2 = .04235 /s P3 = PM/ M3 P3 = 1.064 E -4 /s Therefor power performance function is Pe = 1608455 e + 0.04235 e2 1.064 E-4 e3 Drive shaft Engine

First Gear Second Gear Third Gear Fourth Gear Reverse Gear

Gearbox

Wheels

Electrical Circuit

Ergonomics and Validation

ERGONOMIC PARAMETER Visibility Front visibility distance VALUES 67 61.59

Seat rest angle

Cock pit length Cock pit height
Design Aspect Roll Cage

20
79.48 53
Plan and Analysis Methodology FEA : Front Impact Test Side Impact Test Rear Impact Test Roll over 1. ADAMS shall be used to determine the performance of the suspension. 2. Load will be applied on the vehicle in dynamic and static conditions to test the performance of the suspension. The system that gives the required turning radius and the least steering effect will be selected. The system that gives stopping distance closest to 11.14 m and best suitable will be selected. To select the required gear ratio, which gives torque and speed. To design the kill switch and the various circuitry Result Achieved Below yield stress Below yield stress Below yield stress Below yield stress Achieved

Criteria SAE BAJA Rule Book Section 3

Suspension

To provide good cushioning against shocks, without failure.

Steering

Brakes Transmission Electricals

To design a steering mechanism which satisfies Ackermanns mechanism and also provide self centering effect and avoids nervousness. To design a braking system which provides comfortable stop at a distance of 14.3m To increase the torque and speed of the vehicle to meet the demands of the hill climbing test. To provide fool proof lighting and sound circuits

Achieved

Achieved Achieved Achieved

Co-Ordinates and Innovations

The centre of gravity for the entire vehicle is located at (995,189,-1050) which is below the seat
Component Engine Gearbox Seat Driver Steering (X,Y,Z Coordinates) (339,316,-1230) (247,307,-851) (671,566,-1050) (973,529,-1100) (1550,502,-1050) (314.6,163,-162) (311,163,-1950) (1780,165,-296) (1780,165,-181) (314.6,158,-112) (315,158,-1960) (1780,158,-286) Weight (kg) 30 15 2 80 6 1.265 1.265 1.265 1.265 20.246 20.246 20.246

INNOVATIONS:
Fly ash incorporation in brakes Piezo Electric power generation Roll cage diameter optimization

Back Right Brake Back Left Brake Front Right Brake Front Left Brake Back Right Tyre Back Left Tyre Front Right Tyre

Front Left tyre Front Right Suspension

Front Left Suspension Back Right Suspension Back Left Suspension Brake Pedal Clutch Pedal Acceleration Pedal

(1780,158,-1820) (306,367,-430)
(306,367,-1600) (1790,337,-585) (1790,337,-1520) (1730,132,-1090) (1730,132,-981) (173,132,-878)

20.246 1.2985
1.2985 .5234 .5234 .586 .586 .586

Team Faculty Advisor : Dhanasekhar Team Captain : Mohammed Zaid

S.No 1 2 Name Aravindh Adithyan Role in Team Machinist / Brake Design / Administration

3
4 5 6 7 8 9 10 11 12 13

Harish
Harikrishnan Arun Benraja Madumitha Sahithya Sabari Gireesh Pawan Kumar Sai Vishnu Gowri Shanker Dhivaker Mohammed Zaid

Inspection / Machinist
Co-Driver / machinist Electrician Design Machinist / Steering Design / Welding Inspection / Machinist Machinist / Administration Design / Welding Machinist / Driver Stocker / Machinist

14
15 16 17 18 19 20 21 22 23 24

Manikandan
Mahendran Mohammed Mudassir Hariharan Manoj Somoosay Varun Vaisikan Rahul Dharmarajan Vaishnavi Srinivasan Soorya

Inspection / machinist
Machinist Machinist / Stocker Machinist / Stocker Machinist / Steering Inspection / Stocker Electrician Design / suspension Machinist / Suspension Machinist / Steering Machinist / Brakes

25

Deepak

Welding