The document provides information about BAJA SAE India, an intercollegiate engineering design competition. It discusses that the objective is to simulate real-world engineering projects and challenges. Teams must design, build, test, and compete with a vehicle within the competition rules. There are two vehicle categories: internal combustion and electric vehicles. The competition consists of three phases - preliminary, virtual, and physical dynamic events. It then provides overviews of the key vehicle systems and departments involved in BAJA vehicles, including frames and ergonomics, suspension and steering, powertrain, brakes, and statics. It discusses the components, design considerations, and analysis methods for each department.

2. What Is BAJA??
BAJA SAEINDIA is an intercollegiate engineering design competition for undergraduate
engineering students. The objective of the competition is to simulate real-world engineering
design projects and their related challenges. Each team is competing to have its design
accepted for manufacture by a fictitious firm. The students must function as a team to design,
engineer, build, test, promote and compete with a vehicle within the limits of the rules. They
must also generate financial support for their project and manage their educational priorities.
BAJA SAEINDIA is conducted for two vehicle categories:
1. M-BAJA – I. C. Engine Vehicle
2. E-BAJA – Battery Operated Vehicle
BAJA SAEINDIA 2023 Events will be conducted in 3 Phases –
1. Phase 1 - Preliminary Round
2. Phase 2 - Virtual Event
3. Phase 3 - Physical Dynamic Event

3. DEPARTMENTS
IN BAJA
1.FRAME & ERGONOMICS
2.SUSPENSION & STEERING
3.POWER TRAIN
4.BRAKES
5.STATICS

4. SUSPENSION &
STEERING

5. Types of suspension
• Macpherson Suspension.
• Double Wishbone Suspension.

6. Types of Steering:
• Ackerman Steering
Ackermann steering is that the inner wheel (closer to ICR) should steer for a bigger
angle than the outer wheel in order to allow the vehicle to rotate around the middle
point between the rear wheel axis. Consequently the inner wheel travels with a
slower speed than the outer wheel.

7. Dampers used in Baja Vehicle: Steering Rack Used in Baja Vehicle

8. POWER
TRAIN

9. IT IS THE POWER DELIVERY SYSTEM OF A VEHICLE.
BAJA VEHICLE CONSISTS OF FOLLOWING POWER TRAIN
COMPONENTS:
❖ CVT (CONTINUOUSLY VARIABLE TRANSMISSION)
❖ REDUCTION GEAR BOX
❖ HALF SHAFTS
❖ ENGINE

10. ENGINE:
• M-BAJA ENGINE IS A STANDARD BRIGGS AND STRATTON 10HP
VANGUARD ENGINE.
• NO MODIFICATIONS OR TUNING OF ENGINE IS ALLOWED.
• DRIVER GEAR PULLEY IS ATTACHED TO ENGINE OUTPUT SHAFT.
CONTINUOUSLY VARIABLE TRANSMISSION (CVT):
• IT IS A BELT AND PULLEY TRANSMISSION SYSTEM.
• CENTER DISTANCE IS 242MM.
• LOW RATIO IS 0.43:1 AND HIGH RATIO IS 3:1.
• CV-TECH CVT WAS USED.
• CVT CASING WITH RIGID MESH OR METAL SHEET IS MANDATORY.

11. HALF SHAFTS:
• HALF SHAFTS ARE POWER TRANSMITTING MEMBERS TO THE WHEELS.
• WE HAVE USED CUP JOINT SHAFTS (OEM COMPONENT)
• THERE ARE TWO TYPES OF SHAFTS:
1. CUP JOINTS
2. UV JOINTS
REDUCTION GEAR BOX:
• IT IS USED TO MULTIPLY THE TORQUE FROM THE ENGINE.
• WE USED A GEAR BOX WITH RATIO OF 13:1
• GEAR BOX IS EQUIPPED WITH SPUR GEARS AND HP GEAR LUBRICANT
IS USED.
• DRIVEN GEAR PULLEY OF CVT IS CONNECTED TO GEAR BOX.

13. STATIC DEPARTMENT

14. WHAT DOES STATIC
DEPARTMENT CONTAIN?
• Phase 1:
1. Design Presentation
• Phase 2:
1. Design
2. CAE
3. Cost
4. Sales
5. Go Green
Total static events consists of 200 points and 40 extra points if selected for final events.

15. PHASE 1: DESIGN
PRESENTATION
• It is an online presentation which consists of preliminary design idea.
• In this presentation we have to brief them about our new design by comparing
to our previous year design.
• Explain them how the new design is efficient than previous year design.

16. PHASE 2: STATIC EVENTS
1. Design Event: this event explains our final design and we will be
finalizing the design and no further changes are accepted.
2. CAE Event: This event explains about the mechanical analysis done on
the frame of the BAJA.
3. Cost Event: This event briefs the overall cost of the vehicle.
4. Sales Event: This event is a hypothetical event. Which means we have
to float an ATV producing company and inspire the investor to invest in
our company.
5. Go Green Event: This event is an innovation event, in which we have to
suggest a way to reduce pollution emitted from BAJA and we should
also make a prototype of our idea.

17. OTHER MANDATORY
SUBMISSIONS
• DVP
• DFMEA
• IPG Car maker
• Indemnity Bond
• Engineering Drawings
• Design Specification sheet

18. POINTS DISTRIBUTION IN
STATIC EVENTS

19. FRAME & ERGONOMICS

20. Frame and ergonomics

21. Automobile frame is the skeleton (structural backbone) of any vehicle chassis. It is the foundation
for carrying the engine, transmission system, steering system, brakes by means of spring, axle,
rubber pads etc.
Frame is the basic frame work of the automobile chassis. It supports all the parts of the automobile
attached to it. All the systems related to automobile like power plant, transmission, steering,
suspension, braking system etc. are attached and supported by it only. The frame should be
extremely rigid and strong so that it can withstand shocks, twists, stresses and vibrations to which
it is subjected while vehicle is moving on road.
Functions of Chassis Frame:
To carry load of the passengers, goods or cargo carried in the body.
To support the load of the body, engine, gear box etc.,
To withstand the forces caused due to the sudden braking or acceleration
To withstand the stresses caused due to the bad road condition.
To withstand the centrifugal force caused by cornering of the vehicle.

23. ANSYS structural analysis software is trusted by organisations around the world to rapidly solve complex structural
engineering problems with ease. Finite element analysis (FEA) tools from ANSYS provide the ability to simulate every
structural aspect of a product:
Linear static analysis that simply provides stresses or deformations
Modal analysis that determines vibration characteristics
Advanced transient nonlinear phenomena involving dynamic effects and complex behaviour
All users, from designers to advanced experts, can benefit from ANSYS structural analysis software through: the renowned
ANSYS Workbench intuitive workflow; wide variety of material models; element library quality; solver speed, robustness and
accuracy; and the ability to model every product — from single parts to very complex assemblies with hundreds of components
interacting through contacts or relative motions.

24. BRAKES

25. The type of braking system used in baja vehicle is Hydraulic braking system
1.Hydraulic braking system runs on brake fluid, cylinders, and friction. By creating pressure within, glycol ethers
or diethylene glycol forces the brake pads to stop the wheels from moving.
2.The force generated in the hydraulic braking system is higher when compared to the mechanical braking
system.
3.DOT 3 brake fluid is preferred because DOT 3 brake fluid will absorb less water than DOT 4 from the air over
time.DOT 4 brake fluid can also be used as DOT 4 brake fluids have higher minimum dry and wet boiling
points
Types of brakes
1.Disc brakes
2.Drum brakes
CAUTION!WITH BRAKE FLUID:Highly reactive that it can damage the skin and damage the metal easily.

26. The main components used for braking in BAJA vehicle:
KBX CALIPER TANDEM MASTER CYLINDER BRAKE PEDAL
BRAKE FLUID LINES 3-way splitter banjo bolts bleeder
bolts

27. Problems faced
1.Assembly of the master cylinder and brake pedal
2.Sealing each and every gap with proper sealant like teflon tape
3.Bending of brake fluid lines which cause damage to
brake lines
4.Broken pressure switches
5.Bleeding of the brakes again and again

28. Rules according to the SAE Baja
1.Must use Hydraulic braking system.
2.Brakes Effectiveness will be allowed only if the rotation of all 4 wheels
stops and the vehicle comes to stop at a place instantly
3.Brake light must have homologation
marking engraved on the lens/housing part
of the lamp
4.Inboard Braking rotors should meet the rules
of the powertrain Guard and should prevent the
unintentional contact of hands with the rotor

29. 1.Inboard braking system is used for the present baja vehicle which makes it easy while
assembling.
2.Out-Board Brakes can be used for better braking efficiency,but to use this brakes there
has to be knuckles designed to support the calipers and discs.
3.Solidworks software is used to design and develop the components.
4.ANSYS is used to analyze the rotor strength,heating and cooling while braking.
5.Weight,cost and efficiency are considered all the time.

30. Calculations
1.Three equations of motion which we know in 9th
standard are used to find the stopping distance
and stopping time of vehicle when brakes are
applied.
2.pedal ratio and master cylinder bore
Length,piston diameter,rotor size,contact
area,brake pads measurements,etc. are
taken to calculate the braking force

31. Vacancies in departments
● People who are interested to join the team, has to undergo
screening test and an interview.
● Departments with vacancies:
I. Frame and Ergonomics
II. Suspension and Steering
III. Power train
IV. Brakes
V. Static

32. Cost of main materials:
1.Registration Fees:
Phase 1,2&3: 71,000/-
2.Frame :
AISI tubes : approx. 22,000/-
Welding charges : 35,000/-
3.Power Train:
CVT: 1,00,000/-
Shafts(4) : 70,000/-
4. Suspension:
FOX Dampers(4): 3,20,000/-
Uprights(4) : 30,000/-
5. Brakes:
Wilwood master cylinder(2): 20,000/-
Wilwood brake calipers(4): 40,000/-
Total: 7 to 8 lac, out of which we get sponsor
from college and other sources at least half of
the total amount. Then we are left with around
4.5 lac per person.
4.5 lac distributed among 30 members is
15,000 rupees per person.

33. THANK YOU