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S
INDIAN INSTITUTE
OF
TECHNOLOGY PATNA
ENDURANCE SCORE
:0
TOTAL SCORE :
LESSONS
LEARNT
LESSONS
RECTIFICATION
(THIS YEAR)
Weight reduced by 62 %
Front
Rear
660 grams
780 grams
Old
Proposed
LESSONS
LESSONS
LEARNT
RECTIFICATION
(THIS YEAR)
Excess Vibration
Performance
Electrical Changes
CVT introduced
Automatic Gear change
Optimum engine performance
Easy Handling
PARAMETER
OLD v/s
PROPOSED
OLD
PROPOSED
Kerb Weight
360 kg
191 kg
FAW / RAW
40:60
43:57
54" / 70"
46"/ 60"
64"/ 94"
54" / 82"
Double Wishbone
Double Wishbone
Double Wishbone
Trailing Arm
Height of C.G.
22"
23"
Ground Clearance
12.5"
12"
Transmission
Direct Coupling
CVT
Max Speed
59.37 km/hr
60 km/hr
Max Acceleration
5.21 m/s2
8.17 m/s2
Gradability %
53.16 %
69 %
3.042 m
2.85 m
Suspension
Coil Spring
Tyre
24"x10"x12"
22"x8"x10"
Front :
Suspension
Rear :
MATERIAL
TUBINGS
Wall
Thickness
OD
AISI 4130
(Chromoly
)
0.065 in
1.25 in
Length
72.14 in
Height
50 in
Width
32.51 in
No. of Welds
40
Total Weight
40 kg
Reach Envelope
Yield Strength
ABS
Plastic
Sheet
42.5 - 44.8
MPa
Bracket
Visibility
CAE PROCESS
FRONT
IMPACT(25000N)
MATERIAL
ROLL OVER(16000N)
AISI
4130
AISI
1018
Yield
strength
460 MPa
370 MPa
Poison ratio
0.29
0.27
Tensile
strength
560 MPa
440 MPa
%Elongation
21.5%
15%
Density
7850
kg/m3
7870
kg/m3
Composition
0.3% C
0.2% C
Weldability
Post Heat
Stress
Low
Carbon
Front/Rear/Side
Impact
Rollove
r
Crash
velocity
60Km/hr
10 ft
Impact
Time
0.20 s
0.1 s
SIDE
IMPACT(25000N)
Max Stress
Coarse (431)
289 MPa
Medium
(1073)
323 Mpa
Force
Fine(1585)
25000 N 16000N
Applied
LOAD CASE
FORCE
STRES F.O.
S
S.
330 MPa
DEFORMATI
ON
FRONT CRASH
25000 N
148
MPa
3.11
2.6mm
SIDE CRASH
25000 N
358
MPa
1.28
7.74mm
SUSPENSION
PARAMETERS
FRONT
REAR
Suspension
Type
Double
Wishbone
Trailing Arm
Natural
Frequency
1.7 Hz
1.95 Hz
Motion Ratio
0.7
0.7
Spring
Stiffness
17.5 N/mm
27.5 N/mm
Ride Rate
8.6 N/mm
13.5 N/mm
Damping Ratio
0.45
0.45
Wheel Travel
203 mm
114 mm
Suspension
Travel
142 mm
80 mm
FRONT
Roll Center
- 54.6 mm
PARAMETERS
Roll Rate
102.6
Nm/deg.
King Pin inclination
Zero
VALUES
161
Nm/deg.
5
A -Castor
Arms angle10.75" U / 11"
5 17"
L
Scrub radius
54.6mm
Static Camber
-1
Toe-in
0.25"
FOS : 3.21
FOS : 2.85
REAR
FOS : 2.67
FOS :
2.08
BRAKES
PERFORMANCE PARAMETERS :
Bias Ratio (Front: Rear).
2
PROBLEMS
1.Bleeding
2.Unbalanc
ed
Circuit
RAKING CIRCUIT :
PART
SPECIFICATION
S
3240.09
N
Maximum Deceleration
10.80
m/s2
10.79 m
Perception Distance
15.79 m
2365.23
N
577.76 N
400 N
Master
Cylinder
N/A
Disc
Aviator
190mm/130mm
Wt. Transfer(40Kmph0Kmph)
40.36%
Calipers
CBZ Xtreme
-Right
Suzuki GS Left
Piston dia.
26mm (2 nos.)
268.22 mm
0.65
Mean Braking
Rad.
81mm
Area
617.7 in2
Caliper pad
Braking Torque(One
Wheel)
3.75:1
301.76 Nm
(Front)
150.88 Nm
(Rear)
Tie Rod
Steering
Wheel
Length
Material used
4130
OD : 0.625
Diameter
Max Turn Angle
100%
4.46"
20.67
Inside
37"
Outside 26.17"
2.85m
7.5"/19.01"
15"
98mm
Oversteer
Behavior
3.27 rev.
29.97 mm/
rev.
11.52"
:
AISI
Wall: 0.035"
10"
588.6
WHEEL
Kings KT 102
Traction
Dimension:
22"x8"x10"
10
POWER TRAIN
Engine Specification
Engine
Number
20S232 0036
Power
(3800Rp
m)
10.5 Hp
Transmission
Specification
Torque
19.66 N-m
(2600Rp
Mounted on MS plate
m) anti vibration
using
rubber pads
Acceleratio
8.17 m/s2
n
CVT ratio
0.43:1 3:1
Output ratio
7.74 54
Tire
Dimension
(in)
22"x8"x10"
Drive axle
angle(static)
14.89
Vehicle
Mass
304 kg
Acceleration
m/s2
Acceleration
m/s2
Gear ratio
Grad69%
ability %At velocity of 7km/h
Grad-ability
Velocity km/hr
Velocity
17
11
WEIGHT
& COST
COST
& WEIGHT
Weight : OLD
Weight : PROPOSED
Unsprung*; 15%
Unsprung*; 17%
Rider; 32%
Rider; 37%
Chassis; 13%
Ergonomics; 3%
Chassis; 25%
Electrical System; 3%
Engine; 7%
Steering; 4%
Cost : OLD
Miscellaneous; 9%
Safety; 20%
Electrical System; 4%
Steering; 4%
Wheels; 13%
Chassis; 14%
Suspension; 11%
Engine; 13%
Transmission; 9%
Brakes; 3%
Total Cost =
Ergonomics; 3%
Engine; 8%
Transmission; 13%
Steering; 5% Fuel Tank; 2%
Electrical System; 3%
Cost : PROPOSED
Miscellaneous; 8%
Safety; 11%
Chassis; 11%
Electrical System; 4%
Suspension; 10%
Steering; 4%
Engine; 12%
Wheels; 10%
Brakes; 10% Transmission; 21%
Total Cost =
12
PROJECT
PLANNING
-Gantt Chart
13
VALIDATION
PLAN
DFMEA
Item
Name
Failure
Mode
Failure
Cause
Frame
Structura
l/Safety
Engine
Mechanic
al
A-arms
Mechanic
al
High
load/Shock
Dirty air &
fuel,
Spark Plug
Shock/
Impact load
Tie Rod
Wheels
Mechanic Damaged by
al
debris
Safety
Test
Operation
Effect/Hazards
Frame Bends
Explosion
Possible, Engine
stop
Suspension
compromised
Inability to steer
Safety
Effects/H
azards
Risk to
Driver
Safeguards
Actions
High Factor of
Safety
Strain Gauge
Serious
Injury
Optimized
Position
Regular Air
Filter
& Spark plug
Serious
Injury
High factor of
safety
Strain Gauge
Serious
Injury
Optimized
position
Diligent
Testing
Inappropriat
Risk to Plan Correct air
Precautionary
Design Validation
e
Tire burst/deflate
driver
pressure
check
Parameter/constraint
Implementation
air pressure
Welding Test
Tilt test
Straight line
stability
14
TEAM STRUCTURE /
COLLEGE FACILITIES
Departme
nts
Chassis
Steerin
g
Brakes
and Tires
Abhishek
Rathore
Om Prakash
Sahu
Ram
Agarwal(VC)
Kunal Kanoi
P Rahul
Palani
Pranay
Prakash
(C)
Sai
Manish
Vitthal
Pandey
Gaurav
Garg
Prashant
Luhana
Transmis
Karan
sion
Jakhar
Anant
Arya
Alok
Kumar
Shefali
Das
Amit
Pratap
Machining
Suspensi
on
Anpeksh
Saksena
Nitesh
Kumar
Sourabh
Jain
Ravi Anand
Jatin Kalra
Engin
e and
Exha
ust
Electri
cal
Saurabh
Gupta
Kushagra
Jain
Vishal
Singh
Piyush
Bhandar
i
Ayushi
Priyam
Manufacturing
Universal Milling
Wire EDM
Conventional
Lathe
3D Printing
Grinding Machine
Pipe Bending
Machine
Welding-Arc,
Mig,Tig
Drilling Machine
Testing
Machines
Universal
Testing
Machine
Hardness
Testing
machine