This document contains information about Karan Katna's work and qualifications. It summarizes his role in various engineering competitions and clubs from 2014-2016. It also provides technical details about vehicles he helped design for SAE competitions, including engine specifications, component designs, performance calculations and diagrams of the vehicles.

1. My Work
All the pictures in the following pages
are produced by Karan Katna
Karan Katna
#07696363183
Karan.katna@gmail.com

2. My Profile
• Mechanical Engineer
• Team Captain SAE SUPRA 2016
• Team Vice Captain SAE BAJA 2015
• Team member SAE SUPRA 2015
• Team Captain ASME HPVC 2015
• Team member ASME HPVC 2014
• President- Motosports Club, Punjabi University
• Joint Secretary- Crispolatieia 2k15
• Driver- Formula Student 2016
• Student Co-ordinator, Placement Cell, Punjabi University, Patiala
• Orgnaizing member- Teqtrendz Club, Punjabi university, Patiala

3. SAE SUPRA 2k16

4. Custom designed fuel tank
Fuel Tank: Aluminium sheet
metal (Corrosion Resistant).
-Light Weight.
-Low Price.
-Ease of manufacturability.
-Baffle is provided to have proper
fuel transfer while cornering.
POWERTRAIN AND MOUNTING CONSIDERATIONS :
Engine Selection(KTM 390 Engine Selected):
1. Conformity to rules..
2. From track study , we required a balanced
, agile (36kg weight) engine with power of
at least 40hp and torque 35Nm. It best
suites with the requirement.
3. Its power-band lies in the required rpm
range of 8000-9500 rpm on which the
vehicle will run most of the time.
4. Fuel efficient as well as cost efficient
engine.
Intake Restrictor :
Dimensions 56mm-20mm-56mm
Converging angle 12 degree
Diverging angle 6 degree
Material Aluminium
Light weight as well as smooth
surface.
Exhaust:
Mild steel tube for exhaust
length for max. horsepower
at 7000rpm.
Light weight filtered
aluminium muffler is used
with noise cancellation
advancement.
Electronics:
Bosch ECU stock used .Push
button switch and kill –switch
actuated.
Piezoelectric injectors used.
FUEL TANK
Powertrain
Manufacture KTM 390 duke
Bore / Stroke / Cylinders / Displacement 89/60/1/373.2
Throttle Body / Mechanism 48mm throttle body , butterfly-valve
Max Power design RPM 43.5PS@8500rpm
Max Torque design RPM 35Nm@7000rpm
Ignition System Computer-controlled digital transistorized with electronic advance
Oiling System (wet/dry sump) wet sump
Coolant System water cooled
Engine Mount analysis using ANSYS
Muffler

5. ACCELERATION TABLE (m/s^2)
Gear 7000 RPM
1 12.37
2 8.46
3 6.3
4 5.23
5 4.47
6 3.85
VELOCITY TABLE (km/h)
GearRPM 5250 7000@MAX Designed
Torque
8500@max designed
BHP
10500
1 16.11 21.52 26.122 32.24
2 25.46 33.95 41.23 50.93
3 34.199 45.6 55.38 68.4
4 41.2 54.94 66.71 82.4
5 48.19 64.25 78 96.37
Power Transmission
Open Differential • Lesser transmission loss due to decrease in
no. of gears
• Less weight
• Cost effective
Chain Type 520 X-Ring Chain
Half shaft considerations
• Material Used- Mild Steel
• CV- shafts which allow a rotating shaft to transmit power at
variable angles.
• Decreased loss due to vibration
Primary Reduction 2.667(80/30)
1st gear 3.333(40/12)
2nd gear 2.117(36/17)
3rd gear 1.571(33/21)
4th gear 1.304(30/23)
5th gear 1.115(29/26)
6th gear 0.962(26/27)
Secondary Reduction 3.333(50/15)
Transmission
Engine

6. Front View
Side View
Rear View
Overall Length 96”
Wheel Base 63.5”
Overall Height 45”
Overall Width 59.5”
Track Front 52”
Track Rear 49”
SAE SUPRA 2K15

7. POWERTRAIN
Engine should be light weight , easily available and power
band should lie in desired rpm range.
 Restrictor : Venture pipe design is chosen for smooth mass
flow and minimum pressure difference.
Open differential is used to minimize power losses.
 The engine mounts should be made stiff enough to
reduce the possibility of failure.
 Vibrations of engine to be controlled efficiently.
Powertrain
Manufacture / Model Honda MC41/CBR 250R
Bore / Stroke / Cylinders /
Displacement
76/55/1/249.6
Compression ratio 10.7
Throttle Body / Mechanism 38mm throttle body ,
butterfly-valve
Max Power design RPM 26.15Bhp@8500rpm
Max Torque design RPM 22.9Nm@7000rpm
Ignition System Computer-controlled digital
transistorized with electronic
advance
Oiling System (wet/dry
sump)
wet sump
Coolant System liquid cooled
CFD analysis Using ANSYS 14 for Air Intake
Pressure and Velocity
Intake Restrictor :
Dimensions 38mm-20mm-38mm
Converging angle 12 degree
Diverging angle 6 degree
DESIGN CONSIDERATIONS :

8. Component Specification
Front Hubs Ford Ikon
Knuckle(Uprights) Custom Designed
Knuckle Material Aluminium 6063
Rear Hubs Ford Ikon
Half Shaft Considerations
CV-Shafts which Allow a rotating shaft to
transmit power at variable angles.
Decreased loss due to vibration
Material : Mild Steel
Power Transmission
Open Differential •lesser transmission loss
due to decrease in no. of
gears
•lesser weight
•Cost effective
Chain Type 520 O-Ring chain
CHAIN DRIVEN OPEN DIFFERENTIAL
Custom designed fuel tank
Fuel Tank: Aluminium
sheet metal (Corrosion
Resistant).
-Light Weight.
-Low Price.
-Ease of manufacturability.
-Fuel Pump is provided to
have
Tires Used Hoosier
20 x 7.5 – 13
Tread
Width
7”
Adhesion
coefficient
0.9

9. VELOCITY TABLE (km/h)
GearRPM 5250 7000@MAX
Designed Torque
7500 8500@max designed
bhp
10500
1 14.9 19.86 21.302 24.142 29.822
2 23.455 31.27 33.51 37.978 46.914
3 31.605 42.142 45.15 51.17 63.21
4 38.08 50.77 54.40 61.65 76.16
5 43.48 59.37 63.63 72.10 89.066
6 51.612 68.82 73.73 83.61 103.232
ACCELERATION TABLE (m/s^2)
Gear 7000 RPM
1 8.6889
2 5.5184
3 4.08951
4 3.3991
5 2.9064
6 2.5076
TRACTIVE EFFORT(N)
Gear Tractive Effort
1 2552.0186
2 1622.409
3 1203.970412
4 999.35
5 854.5047
6 737.24986
CALCULATIONS
Maximum tractive effort that Hoosier tyres can hold =2764.681N
Primary Reduction 2.808(73/2)
1st gear 3.333(40/12)
2nd gear 2.117(36/17)
3rd gear 1.571(33/21)
4th gear 1.304(30/23)
5th gear 1.115(29/26)
6th gear 0.962(26/27)
Secondary
Reduction
3.428(48/14)
Gear Ratio’s Table

10. SAE BAJA 2K15 Vehicle
60”

11. Side View
Side View
Top ViewRear View
54”
75”

12. POWER TRAIN
Gear Overall Gear Ratios Max. Speed
(kmpr)
(at 3800)
Max.
Speed(kmpr)
(At 3500)
Traction
Force(N)
Gradeability
%
1 25.39:1 16.47 15.17 1537.75 60.8
2 15.06:1 27.77 25.58 912.11 32.58
3 9.16:1 45.66 42.05 554.78 19.07
4 6.15:1 68 62.64 372.48 11.92
Rev. 31.28 13.37 12.31
TRANSMISSION : PIAGGIO APE
Taking
Transmission efficiency= 0.9
Briggs and Stratton 4 stroke 305cc
Engine
Traction 1542 N
Transmission
Configuration
Piaggio ape. 4
forward +1 reverse
Max Torque 19.65Nm
Max speed 65km/hr
Maximum gradient 44%
Tyre Dimensions 23X7X12
Total Vehicle Mass= 300kgs
12

13. Exploded view of wheel assembly
Component Specification
Front Hubs Custom Design
Front Hub Material Aluminum 6061-T6
Knuckle(Uprights) Custom Designed
Knuckle Material Aluminium 6061-T6
Rear Hubs Stock Maruti 800 hubs
Axle Shafts Stock Piaggio Ape axle shafts
coupled with Maruti 800 Axle
Shafts
13

14. ASME HPVC 2K14-15