The document provides technical specifications and design details for an electric vehicle called ANDROSPHIN. It includes the vehicle's dimensions, weight, performance characteristics, component designs, analysis, and project planning. Key details are the vehicle's wheelbase of 1517.41mm, max speed of 60kmph, stopping distance of 7.867m, and total weight of 294kg. The chassis is made of AISI 4130 steel alloy. Components like the suspension, brakes, steering, and powertrain are also described in detail along with analysis of stresses and forces. The project timeline is outlined in a Gantt chart spanning 2017-2018.

1. Team
ANDROSPHIN

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

3. ROLL
CAGE
DESIGN
Human Ergonomic
Anthropometric
Model

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