The document provides specifications for an electric vehicle including: - Dimensions of 70 inches long, 55 inches wide, with a 45 inch wheelbase and 35 inch track. - The roll cage is made of AISI 1018 steel that is 1 inch in diameter and 3mm thick. - It has a 12 kg roll cage, 170 kg total mass, 1 inch ground clearance, and can reach speeds of 65 kmph. - Finite element analysis was conducted and showed maximum deformations of 0.67mm on front impact and 0.13mm on rear impact. - Ergonomics and safety aspects are maintained with a spacious cockpit and components within reach. - The braking system can

1. SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY
(HYDERABAD).

2. Parameter Value
vehicle length 70 inch
vehicle width 55 inch
Wheel base 45 inch
Wheel track 35 inch
Roll cage material AISI 1018
Tube dimensions 1 inch OD
3 mm thick
Roll cage mass 12 kg
Total mass 170 kg
Ground clearance 1 inch
Battery 12 V
Max speed 65 kmph
Brake Hydraulic disc
brake
Steering Pitman arm
Tyre 10*4.5*5 (front)
11*7.1*5 (rear)
VEHICLE SPECIFIATIONS

3. Material Density
(gm/cc)
Yield
strength
(Mpa)
Outer
diameter
(mm)
Thickness
(mm)
Bending
strength
( N-m)
Bending
stiffness
(N/mm)
Hardness
(BHN)
Tensile
Strength
(Mpa)
Elastic
Modulus
(Mpa)
Poisson'
s
ratio
AISI
1018
7.87 370 25.4 3 387.38 134.78 126 440 205 0.29
MATERIAL SELECTION FOR CHASSIS
Length 59 inch
Width 29 inch
weight 12 kg
DESIGN METHODOLOGY
Main Dimensions

4. FINITE ELEMENT ANALYSIS
FRONT IMPACT REAR IMPACT
Total Deformation(max) = 0.67 mm
Load applied = 7.5 G
Total Deformation(max) = 0.13 mm
Load applied = 7.5 G
Equivalent Stress(max) = 285.6 Mpa
Load applied = 7.5 G
Equivalent Stress(max) = 138.9 Mpa
Load applied = 7.5 G

5. SIDE IMPACT TORSION
Case Total applied
Force (G)
Max Stress
(Mpa)
FOS Max
Deformation(mm)
Front impact 7.5 285.65 1.20 0.67
Rear impact 7.5 138.90 2.80 0.13
Side impact 5.0 662.72 1.07 1.30
Torsion 43 N-m 26.17 1.68 0.022

6. ERGONOMICS AND SAFETY
MAINTAINED
• SPACIOUS COCKPIT.
• INTEGRATION OF 95 PERCENTILE MALE IN COMFORTABLE POSITION.
• CLEAR LINE OF SIGHT.
• ALL THE PARTS ARE WITHIN REACH TO ACCESS.
• COMPLETE DRIVER’S KIT.
INNOVATION
1. THINKING TO HAVE A BRAKE FLUID SENSOR OVER MASTER
CYLINDER TO KNOW THE LEAKAGES.
2. ENERGY GENERATION USING EXHAUST GASES

7. STEERING
Parameters Values
Wheel track 35 inch
Wheel base 45 inch
Mechanism Ackerman steering
(pitman arm)
Tie rod length 13.7 inch
Inner turning radius 1.6 m
Outer turning
radius
2.67 m
Max. inner turning
angle
34.89o
Max. outer turning
angle
24.530
Max Deformation = 0.295mm

8. BRAKING SYSTEMOuter dia of disc 200 mm
Disc thickness 6 mm
Tyre radius 127 mm &139.7
mm
Pedal ratio 6 : 1
TMC piston dia 19 mm
Caliper piston dia 29 mm
Driver effort 100 N
Brake force on TMC 600 N
Pressure inside TMC 4.23 N/mm2
Caliper force 2795.56 N
Frictional force(disc
and pad)
1677.36 N
Braking torque 143.48 N-m
Deceleration 25.36 m/sec2
Velocity 40kmph 50kmph 60kmph 70kmph 80kmph
Stopping
distance(m)
2.43 3.80 5.47 7.45 9.73
Stopping
time(sec)
0.44 0.55 0.65 0.74 0.87
COG LOCATION
Height of COG 6 inch
wheel base 44 inch
Dynamic load
distribution
60 : 40
Brake fluid DOT 3
Fluid max temp. 205 0 c
Max deformation = 0.18mm

9. POWERTRAIN
ENGINE SPECIFICATIONS (IGNITOR)
Displacement : 125cc
Max power : 11Bhp@8000rpm
Max torque : 11Nm@5000rpm
Cooling system : Air cooled
Gear box type : manual
No.of gears : 5(five)
Transmission type : chain drive
Clutch : wet multi plate clutch
Primary reduction : 3.35
Final reduction : 1.92
GEAR GEAR
RATIO’S
MAX SPEED
(Kmph)
ACCELERATION
(m/s2)
1 3.076 20.376 6.32
2 1.944 32.364 1.77
3 1.473 42.87 1.15
4 1.19 52.92 0.78
5 1.038 62.92 0.8
Specifications Displacement
(cc)
Max.power
(bhp)
Max.torque
(N-m)
Availability
(%)
Hero Ignitor 125.0 10.9@8000rpm 11@5000rpm 90
Honda Stunner 124.7 11@8000rpm 11@6500rpm 70
Honda shine 124.7 10.6@7500rpm 10.3@5500rpm 100

10. MANUFACTURING AND COST SUMMARY
COLLEGE FACILITIES
Fabrication Machine Tool
Cutting Hand cutter/Power
hacksaw
Drilling Upright Drill,Radial
Drill, Hand Drill
Grinding Hand,Bench,Surface
Grinders
Lathe operations Centre lathes,Capstan
lathe
Milling Universal milling
machine
Press fitting Mechanical press
Shaping Shaper machine
Welding MIG,Arc,Spot,Gas
welding machine
System Estimated
cost
Approx.
weight
Frame and
body
10000 25 kg
Engine +
Transmission
9000 20 kg
Brakes 6000 2 kg
Wheel 11000 16 kg
Steering 3000 5kg
Electricals 2000 3 kg
Safety
Equipment
12000 1 kg
Miscellaneou
s
5000 10 kg
Total 58000 82 kg
Pipe bending Mechanical bending
machine
Special operations CNC machine centre
17%
17%
10%
19%
5%
3%
20%
9%
Frame and body
Engine+transmission
Brakes
Wheels
Steering
Electricals
Safety equipments
miscellneous
OUTSIDE FACILITIES
BOM and estimated cost

11. PROJECT PLAN

12. DESIGN VALIDATION PLAN (DVP)
S. No Description Acceptance Criteria Test Method Assignedto
1. Tensile Strength Of Pipe Application Based Tensile Strength Test on
UTM
Santhosh
2. Weld Strength Test Weld should not crack or
break
Rapid Hammering Yashwanth
3. Shear Strength of Brackets Application Based Test through Ansys khaja
4. Dimensional Stability Should match with technical
specifications sheet
prepared
Provided tolerance Ravi
5. Engine Mount Durability Not less than 75% energy
should be absorbed by
mounts
Vibration test using
accelerometer
Anil
6. Alignment of Pipes No variation of calibrated
spirit level
CombinationSet Gautham
7. Breakcircuit Noleakages Visual inspection Ashok
8. Kill switches Should workproperly Repeated testing Varun
9. Temperature of Firewall Should not exceed 40 C Using Resistance
Temperature Detector
Varun

13. DFMEA

14. Transmission
Anil - H
Vinay
Sankeerthan
Balu Prakash
Santhosh
Jayasurya
THANK YOU
GEAR INFERNO
Design
Sravan - H
Khaja
Ashok
Pavan
Pranaya
Braking
Mahesh - H
Ravi
Vikram - VC
Shravya
Sai Krishna
Steering
Yashwanth - H
Varun - C
Maneesh
Nikhil – Driver
Gautham