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CIT SAEINDIA BAJA 2018 REPORT
- 2. Wheelbase 1517.41mm Total Length 2121.86mm Rear track width – 1246.2mm Front track width – 1346.2mm Total Width – 792.14mm Total Weight – 294KG Max Speed – 60kmph Stopping Distance – 7.867m Tyres Front – 21-7-10 Rear – 24 -9-12 Weight Ratio FAW to RAW 132.3 : 161.7 OVERALL VEHICLE DETAILS
- 4. Chassis material: - AISI 4130 Tensile strength : 210 GPa (30 x 10^6 psi) Elongation at Break : 18% Alloy Composition (%): - (Fe): 97.3 to 98.2 (Cr): 0.8 to 1.1 (Mn): 0.4 to 0.6 (C): 0.28 to 0.33 (Si): 0.15 to 0.35 (Mo): 0.15 to 0.25 (S): 0 to 0.040 (P): 0 to 0.035 Factor of safety – 2.8 MESH : - NODES - 366273 ELEMENTS - 1183251 Front Impact Rear Impact CAE PROCESS TEST APPLIED LOAD (N) MAX DEFORMATION (mm) MAX STRESS (Mpa) YEILD STRESS OF USED MATERIAL Front Impact 29430 2.23 188.3 Rear Impact 29430 6.75 375.27 Roll Over Impact 22,000 3.09 219.4 435MPa Side Impact 14715 13.4 260.15 Roll Over Impact Side Impact
- 5. SUSPENSION Wishbone Material – AISI4130 Wheel Travel – 292.1mm Ground Clearance – 304.8mm CG Height – 533.4mm Rolling Centre Height – 304mm Static Camber - -2˚ Caster - 5˚ King Pin Inclination - 8˚ Toe Angle - 2˚ Damper Travel - 152.4mm Suspension Travel - 39.7mm Type Of Suspension - Double wishbone (unequal/parallel) Suspension Using - Fox Float 3 Upper wishbone Lower wishbone
- 6. Braking Braking Type – X Split Master Cylinder (bore*stroke) – 19.05*31.75 (mm) Brake Type – Disc Brake Area – 2.85e-4 m2 Brake Fluid – Dot 5 Dynamic Weight Transfer – 451.695 N Stopping Distance - 7.863 m Acceleration - 9.796m/s2 Stopping Time – 1.13 sec Kinetic Energy – 17587.07 J Total Brake Force – 2237.7966 N Front Brake Force – 1678.34 N (75%) Rear Brake Force – 559.45 N (25%) Breaking Torque – 897.35NM (front), 559.45 NM (rear) Pedal Force – 147.15 N Pedal Ratio – 5:1 Co-efficient of Friction – 0.7
- 7. STEERING Wheelbase - 1517.41mm Wheel Track -1346.2mm(front), 1246.2mm(rear) Steering Axis Inclination - 8° Steering Wheel Dia - 304.8mm Steering Ratio - 8:1 Rack Length - 355.6mm Rack Travel - 107.95mm Steering Wheel Lock To Lock - 560°(3 turns) Inner Steering Angle - 33.75° Outer Steering Angle - 23.337° Turning Radius - 2.943mtr Ackerman Angle - 28.5435° Tie Rod Length - 504.62mm Toe Angle - 2.386° Steering Wheel Torque - 7.4752 NM Steering Arm Length - 120mm TYPE :- RACK AND PINION
- 8. POWER TRAIN ➢ Torque Curve of the Engine ➢ Power Curve of the Engine Engine Mount Drawing Max power – 3800rpm Max Torque – 17.24 Nm Transmission Unit – CVT Acceleration - 9.796m/s2 Tyres Front – 21-7-10 Rear – 24 -9-12
- 9. BILL OF MATERIAL SL NO ITEM NAME ITEM NO COST PER UNIT TOTAL COST 1 Engine 1 ₹51,150.00 ₹51,150.00 2 Chassis material (AISI 4130 Chromoly) 43mtr ₹650.00 ₹28,140.00 3 Suspension 4 ₹35,700.00 ₹1,42,800.00 4 Brakes assembly 4 ₹4,725.00 ₹18,900.00 5 Steering assembly 1 ₹15,470.00 ₹15,470.00 6 Wheels & Tires 4 ₹30,032.00 ₹1,20,130.00 7 Seating 1 ₹11,780.00 ₹11,780.00 8 Transmission 1 ₹58,117.00 ₹58,117.00 9 Vehicle transportation --- ₹60,150.00 ₹60,150.00 10 Fabrication --- ₹47,500.00 ₹47,500.00 11 Safety Gadgets 2 ₹11,250.00 ₹22,500.00 12 Driver Gear 1 ₹34,550.00 ₹34,550.00 TOTAL ₹5,58,887.00
- 10. • Monthly Project Management Gantt Charts 2017-18 Completed To be completed Not started #weeks Mar Apr May Jun Jul Aug Sept Oct Nov Dec Jan Feb Virtual 123 days Rule Book 25 days Reference Books 20 days Chassis Design 32 days Design Validation 45 days Main Event 237 days Material Testing 15 days Fabrication 146 days Road Test 40 days Analyzing Failures 36 days TEAM STARTED Main Event VIRTUALS 12-Feb 30-Jul 28-Mar 18-Apr 30-Jun8-Apr 2-May 30-Jul 9-Jun 15-Oct 12-Feb 9-Jun 30-Jul 1-Jul 30-Aug 1-Aug 1-Nov 2-Sept 15-Oct 4-Mar
- 11. Part Function Failure Models Precaution Validation Accomplishment Roll Cage Basic Soul of vehicle & to protect the driver When materials reaches to ultimate stress value Use of AISI 4130 Steel having yield strength value 435MPa Welding test Universal Testing Machine Transmission To transmit power from engine to wheels Improper Lubrication Use of ISO Grade oils Speed & Acceleration Road Test Suspension To absorb Shocks & to give smooth drive When coil reaches to solid length Proper calculation & assumption in designing Wheel travel Inch Tape Brakes To reduce the speed when required & emergency stop Circuit failure due to leakage, Worn out break pads Bleeding of vehicles' brake before every run, checking & replacement Braking Test Road Test Wheels To provide good traction Inappropriate air pressure/punct ure tire. Checking of air pressure at every refuel backup extra Tire air pressure Air Pressure Gauge DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN
- 12. TEAM ALLOCATION & WORKSHOP FACILITIES CAE – 3 members CHASSIS – 4 members SUSPENSION – 3members BRAKES – 5 members STEERING – 4 members POWER TRAIN – 3 members ERGONOMICS – 3 members FACULTY ADVISOR – MANJUNATH N