Preliminary Design Report- Dr.

BR Ambedkar NIT Jalandhar

Perianth Racing

ABSTRACT
The objective of this project is to design, analyze and
fabricate a single seated racing vehicle intended for sale
majorly to the non professional racing enthusiasts. The
vehicle is to be designed with the following points kept
in mind

Safety
High performance while being economical
Ergonomics based on anthropometric data
Aerodynamic stability
Easy mass production

The major performance targets have been listed in the

TABLE 1
Table 1 Performance Targets

Top Speed
90 kmph
3.0 m/s2
Acceleration
Maximum Slope Grade Ability 10 degree
Min. Turning Radius

INTRODUCTION

MAIN SECTION

The technique normally used for designing and

analysing SUPRA designs is the use of softwares like
Solidworks, Lotus, Ansys etc. Previously, our team had
used Solidworks and Lotus for designing and analysis of
various components but this year we have taken a step
forward and brought into use, softwares like Ansys and
Suspension analyser. The process that is presently being
followed and will be continued in the future is
Design considerations
Division into sub teams and task assignment
PVC modelling of roll cage
Ergonomic analysis
CAD modelling
Analysis of CAD models
Design of suspension, steering and brake
systems

Analysis of suspension and steering systems

Revision of CAD models

Simulation of component assemblies and subassemblies

Fabrication of chassis
Suspension, steering and brake system
fabrication

Engine and transmission mounting

Final integration of assemblies
Testing and optimization

ROLL CAGE

3.2 m

OBJECTIVE

To design a roll cage considering the factors of safety,

simplicity, manufacturability, durability, comfort and
100% compliance of design with rulebook.
MATERIAL SELECTION

After going through rulebook constraints and market

availability IS 1239 has been selected out of AISI 1018,
AISI 4130 and IS 1239, because it was economical
(compared to AISI 4130), locally available and had
technical advantages (over AISI 1018). TABLE 2

Table 2. Material Comparison Table

Material

Cost
per Yield
10cm(INR)
Strength
(MPa)

Elongation at
Yield Point
(%)

AISI 4130
AISI 1018
IS 1239

56.4
23.6
13.7

25.5
15
18.5

448
366
408

The material specifications used for the roll cage are as

given in TABLE 3

All the design and analysis work has been done using
LOTUS 5.1 and SUSPENSION ANALYZER

Table 3. Material Specification

It has been kept in mind that there might arise a need

to change the camber and to do so, a system has been
designed which uses shims and camber can be varied by
changing the number of shims.

Outer Diameter
Thickness
Yield Strength
Elongation at Yield Point

25.4 mm (1)
2-3 mm
405 MPa
18.5%

The various specifications of the designed suspension

system are given in TABLE 5
Table 5.Suspension Specification

DESIGN METHODOLOGY

Type

Designing on Solid works with verification by making

PVC models and jigs was done in order to use the space
optimally. To increase the strength and therefore
safety, continuous members were given preference as
bending enhances strength due to strain hardening as
compared to welded joints. Use of continuous members
also increases the ease of manufacturing.

Shock Absorber Length

Spring Constant
Camber
Caster
Toe In
Wheel Travel

FINITE ELEMENT ANALYSIS

The results of FEA analysis done on solid works is shown
in TABLE 4
Table 4. FEA Results

Height of Roll Centre

Analysis

Load (KN)

G Force

FOS

Front Impact

23.54

8G

3.52

Rear Impact

23.54

8G

2.444

CG of Vehicle
Roll Stiffness (KN-m/deg)
Scrubs Radius
Frequency (Hz)

Side Impact

11.76

4G

2.62

STEERING

Roll Impact

10.29

3.5G

2.75

OBJECTIVE

Torsion

13.24

4.5G

3.6

SUSPENSION
OBJECTIVE
Designing of suspension was done by considering the
factors of comfort of the driver, steering control, higher
traction, better roll stability, maximum surface contact,
minimization of bump steer and camber gain with
adequate ground clearance.
DESIGN METHODOLOGY
Considering all the geometries available, we have used
double wishbone type suspension with unequal arm
length. This geometry provides various advantages
which are listed below
Independent suspensions
Load distribution at 5 points on the roll cage

Better adjustability

Independent
Double
Wishbone
318.65 mm (Front), 259.42
mm (Real)
35.23 N/mm
(Front), 52.3
N/mm (Rear)
-1.5 degree (Front and
Rear)
4 degree (Front and Rear)
0
101.6mm (Front),101.6 mm
(Rear)
38.6 mm (Front), 47.95 mm
(Rear)
250 mm
0.97 (Front and Rear)
41.27 mm(Front and Rear)
2.66(Front), 1.42(Rear)

The basic aim was to design a steering system with

quick responses, reduction in steering effort and light
weight.
MECHANISM AND GEOMETRY
Rack and pinion mechanism is selected because it is
easily available and light weight.
The Reverse-Ackermann geometry is selected because it
is simple, easy to implement and makes it easier to
accomplish sharp turns; it ensures that the vehicle tires
do not slip during turns that are sudden.
FEATURES
Optimum camber gain with steer, reduced bump steer,
no power assistance is required for steering.
The steering system is going to be tested for
performance by driving the vehicle on tracks in the
shape of FIGURE 8

The basic specifications of the designed steering system

are given in TABLE 7
Table 7. Steering Specification

Min. Turning Radius

Steering Ratio
KPI
Tie Rod Length

3.2 m
4.45:1
8 degree
12.98 in

The overall brake system specifications are given in the

table below.
Table 8. Brake Specifications

BRAKING SYSTEM

Outer Diameter of Disc

Dynamic Load Transfer
Pedal Ratio
Pedal Force
Deceleration

OBJECTIVE

DRIVE TRAIN

To design a braking system which gives minimum

stopping distance, quick responses and less chance of
brake fade as well as simultaneous locking of all the
wheels.

TYPE OF TRANSMISSION

CONFIGURATION
Option considered were disc and drum brakes, chosen:
Disc brakes for both front and rear, reasons for this are
Disc brake dissipates energy more easily due to
proper ventilation available as compared to
drum brake. So chances of brake fade are less in
disc brake.

Since according to problem statement all wheel

should lock simultaneously so disc brake are
more suitable.

Disc brake assemblies reduce the overall weight

of the system and thus provide a better
alternative to drum brakes for the event.
BRAKE FORCE MULTIPLICATION
Out of the various methods hydraulic braking is
preferred due to the following reasons
Small space required

Large force multiplication

Availability
BRAKE CIRCUIT
Diagonal split type circuit has been chosen because
In case of any failure of one reservoir of master
cylinder vehicle could be stopped without any
large variation in stopping distance

This circuit also prevents the vehicle from

yawing effect

200 mm
159 lbs
6:1
50 lbs
1.5 g

Manual transmission has been used reason because

manual transmission (96.5%) can transmit more power
than automatic transmission (85-90%), load capacity of
automatic transmission is lesser hence less reliable.
GEARBOX SELECTION
Factors considered Engine power output curve should
match with gearbox's gear combination, Cost and
Availability, and thus it was decided to use the stock
Karizma gear box.
DIFFERENTIAL
Analyzing the available options for the type of
differential (Open, locking, Limited slip), self
manufactured open differential was decided.
FINAL DRIVE AXLE
Out of two options Double CV joint axle and Double
universal joint drive axle, former is selected because a
CV joint does not cause any vibration during working
and it has more power transmission efficiency 99%.
Table 9. Engine Specification

Maximum Power
Maximum Torque
Engine Coupling
Engine Displacement (cc)

20 BHP at 8000 RPM

19.7 N-m at 6500 RPM
Self-Manufactured
223

TIRE
For both front and rear same size tire has been used
advantage for such practice that it is economical,
favourable for mass production, and only one substitute
is required in case of failure. Size of tires 23x7-10
Table 10.Wheel Assembly

Tire Size
Tire Type
Rim Size
Rim Material
Hub
Upright

175/60
Yokohama)
Treaded
13
Alloy Wheel
en8(080M40)
en8(080M40)

R13

(77H

Fig: Front Impact Test

SAFETY

As far as safety is concerned following measures has

been taken
1. Attenuator (Honey comb Structure)
2. 3 Kill switches
3. 6 harness seat belt with neck restraint and arm
restraint
4. Completely sealed battery
5. Easy and safe exit for driver
6. Firewall (resin reinforced polymer)

CONCLUSION

Fig: Rear Impact Test

By using the above discussed procedure, we aim to

achieve maximum outputs from the resources while
maintaining quality and safety standards. The process of
designing and analyzing has been followed in iterations
which helps to remove the earlier existing flaws and
also helps in improving the performance of the vehicle.

Fig: Side Impact Test

Fig: Roll Over Impact Test

FEA Analysis Of Hub

Side View Of Hub

Front View Of Hub

Design of Upright-

(All views)

Side View

Front View

Isometric View

Top View

CONTACT INFORMATION
Email Id- perianth@nitj.ac.in
Contact No. (+91)98761-98810