Team ID 17355 from Alpha College of Engineering & Technology designed and built an off-road vehicle for the Virtual Baja competition. Their proposed vehicle features improvements over the previous year's design including a lighter roll cage, optimized cockpit area, and improved suspension and drivetrain packaging. Key changes resulted in a weight reduction from 252kg to 196kg while improving specifications such as gradeability, top speed, and braking distance. Lessons from prior years helped focus on effective project management and testing to optimize performance.

1. Team ID: 17355
College Name: Alpha College Of Engineering & technology
Old Team ID: 15322
Car No.:016
Endurance Score: 0
Total Score: 97.2
Awards: Nil
VIRTUAL BAJA 2016

2. Lessons learnt from Previous Year
Previous Year’s Roll cage
Proposed Year’s Roll cage
ROLL CAGE:
• Height of roll cage was reduced.
• Cockpit area was optimized which was very large
in previous buggy.
• RHO which was horizontal previously was given
inclination for aesthetic purpose.
• Suspension mounting links were rearranged.
• Effective drive line packaging which was
cumbersome previous year.
• Reduce width without harming agronomics of
driver

3. - Failure of breaks due to bleeding.
- Knuckles used were readymade and heavy.
Optimizing the turning radius for better
performance in maneuverability and
endurance limit.
Optimum use of
fox.
Acceleration
pedal mounting
was not proper.
Gear shifting was
cumbersome.
Fasteners used
were of low
grades.
• Lack of effective communication between
team members.
• We missed optional event(suspension track)
due to improper time management.
• Endurance practice was not sufficient for the
event.
• Hill climbing was not possible as CG acted
behind the rear tires.
• Overall weight of ATV was high.
Lessons learnt from Previous Year
Vehicle performance in main event Aggregates

4. Component Cost
(2015) INR
COST
(2016)INR
Roll cage 18,125 22,600
Suspension
assembly
1,06,291 1,14.664
Tires 32,000 32,000
Seat 6000 4000
Power Train 85000 10,6,464
Steering System 9550 11,050
Brake System 27000 6334
Electric System 15000 16,500
Machining Cost 11500 19,000
Fasteners 2724 3000
Miscellaneous 6100 7,000
Total Cost 3,19,290 3,42,612
Component Weight -2015
(kg)
Weight-2016
(kg)
Roll cage 44 36
Power train 71.4 59
Knuckle 21 5.8
Tire 32 32
Suspension
assembly
25.44 21
Seat 5 4
Steering
system
8 9
Brake system 27 12
Electric system 5 5
Fasteners 6.5 7
Miscellaneous 7.5 6
Total weight 252 196
Parameters
Previous
Year‘s Vehicle
Proposed New
Vehicle
Overall Width
1495mm
(59”)
1422.4mm
(56”)
Overall Height
1549.4mm
(61”)
1473.2mm
(58”)
Overall Length
2209.8mm
(87”)
2130 mm
(83.85”)
Ground Clearance
355.6mm
(14”)
304.8mm
(12”)
Static Weight
Distribution Ratio
30:70 40:60
Weight of vehicle 252 kg 196 kg
CG height ( from
ground)
20” 21”
Suspension Travel
Front:6.2”
Rear:2.2”
Front: 6”
Rear:4.3”
Top Speed 53 km/hr 56 km/hr
Stopping Distance 12.27 m 9.954m
Grade-ability 27% 45.66%
Turning Radius 3.21 m 2.85m
Cost comparison weight comparison
Specifications
COMPARISON: OLD V/S PROPOSED

5. ROLLCAGE DESIGN PROCESS
(ERGONOMICS)
ROLLCAGE MATERIAL
MATERIAL AISI 4130
OUTER DIAMTER 25.4 mm
WALL THICKNESS 3.4
WELD METHOD TIG WELD
NO. OF WELD
JOINT
54
WEIGHT OF ROLL
CAGE
36 KG
FILLER ROD ER80S-2D
MATERIAL PROPERTY
YIELD STRENGTH 980 MPA
ULTIMATE TENSILE 1040 MPA
CARBON % 0.33
CHROMIUM % 1.1
MANGANESE % 0.6
PHOSPHOROUS % 0.035
SULPHER % 0.04
IRON % 98.2
Ergonomics Considerations:
• Cockpit area optimization.
• Maximum utilization of every single unit of Volume.
• Aesthetic design.
• High factor of safety.
• Improved cone of vision.
• Minimum Hand moment for accessing various component.
• Space frame designed on the basis of 95% Indian male and 5%
Indian female anthropometry data.
Need of design
Concept
development
Wireframe design
Material selection
Stress calculation
FEA
Optimization
Modification
Assembly
DESIGN
STEPS

6. COMPUTER-AIDED ENGINEERING
TEST/
COMPONENT
MATERIAL
Yield
STRENGTH
LOADIN
G CASE
MAXIMUM
STRESS
MAXIMUM
DEFORMATION
FOS
FRONT IMPACT
(roll Cage)
AISI 4130 460 MPa 4G 392.86 MPa 2.34 1.17
REAR IMPACT
(roll Cage)
AISI 4130 460 MPa 4G 366.32 Mpa 2.34 mm 1.25
SIDE IMPACT
(roll Cage)
AISI 4130 460 MPa 4G 329.72 MPa
2.58 mm
1.4
ROLLOVER IMPACT
(roll Cage)
AISI 4130 460 MPa 4G 394.72 Mpa 3.19 mm 1.16
DROP TEST
(roll Cage)
AISI 4130 460 MPa 4G 206.79 Mpa 0.99 2.22
TRAILING ARM AISI 4130 460 MPa 4G 389.26 Mpa 0.75 mm 1.2
FRONT UPPER
ARM (suspension)
AL 6061-
T651
276 Mpa 4G 98.78 MPa 0.3677 mm 2.79
FRONT LOWER
ARM (suspension)
AL 6061-
T651
276 Mpa 4G 74.49 MPa 0.19 mm 3.7
Knuckle (front)
AL 6061-
T651 276 Mpa 4G 43.29 Mpa 0.013 mm 6.37
Knuckle (rear)
AL 6061-
T651
276 MPa 4G 89.29 0.047 3.09

7. Suspension design
Parameters Front Rear
Suspension Type Double Wishbone Semi-Trailing Arm
Ride height 12” 9”
Motion ratio 0.58 0.66
Spring rate 5.572 N/mm 10.737 N/mm
Wheel rate 2.87 N/mm 4.67 N/mm
Angle of correction factor 0.68 0.60
Damping force 2820.3 N 50910 N
Damping ratio at 0.3m/s 0.02 0.01
Spring constant 33 N/mm 72.52 N/mm
Designed natural
frequency
2.5 Hz 2.5 Hz
Sprung mass (60:40) 67.2 Kg 100.8 Kg
Unsprung mass 80 Kg
Suspension travel 6” 8”
Right height 12” 9”

8. Brakes
Parameters Values
Brake type Hydraulic disk
Connection X split
Brake efficiency 80%
Master cylinder diameter 3/4” (bosch)
No. of cylinders in
callipers
2
Callipers make Bybre
Callipers cylinder bore 32 mm
Brake fluid DOT 4
Parameters Values
Pedal ratio 6:1
Pedal effort 392.4 n
Stopping distance 9.954 m
Deceleration 7.848 m/s2
Braking force 3112.13 N
Stopping time 1.52 sec

9. Steering and wheel
geometry
Steering
Parameter
Values
Steering Mechanism Center Rack and Pinion
Turning Radius 2.85
Steering Wheel
Diameter
12”
Ackerman
Percentage
83.86%
Steering Ratio 14:1 (adjustable to 7:1)
Rack length 14”
Rack travel lock to
lock
8.5”
0
10
20
30
40
50
60
TOEANGLE
RACK TRAVEL
Toe Angle
toe angle of
left tire
toe angle of
right tire
0
20
40
60
80
100
120
-10.8 -9 -7 -5 -3 -1 1 3 5 7 9 10.8
ACKERMAN%
RACK TRAVEL (CM)
Ackerman Percentage
Ackerman Percentage
Wheel Geometry
Parameters
Values
Static Camber Angle 0.874
King Pin Inclination 5.676
Caster Angle 5
Scrub Radius 0.12”
Tire size(F/R)
F 22”/7”/12”
R 24”/7”/12
Wheel base Track width
1624.8 mm 1070.8 mm

10. • Grade-ability of the vehicle is 45.66⁰
• Max. Velocity achieved is 55.89 km/h
• Max Tractive Effort available is 2044.74 N
• Accelerations of the vehicle is 5.66 m/s²
• 0-55.89 MPH in 6.37 sec
Parameters
Max. possible
CVT ratio
Min possible
CVT ratio
Input ratio 5.65:1 0.41:1
Gear ratio 13.25:1 13.25:1
Overall ratio 22.45:1 1.59:1
Max. Torque(Nm) 613.42 91.8
Speed (km/h) 7.65 55.89
Tractive Effort (N) 2044.74 306
Air resistance (N) 36.49 1.69
Power Train Design

11. 22,600
106464
19000
32000
114664
4000
11050
6334
16500
3000 7000
COST OUR
roll cage
power train
Machining cost
tire
suspension
seat
steering
breake
electricals
fasteners
miscellaneous
3,42,612 INR
44
71.4
21
32
25.44
5
8
27
5 6.5 7.5
weight OLD
roll cage
power train
knckle
tires
suspension
seat
steering
breake
electricals
252 KG
342612
319290
305000
310000
315000
320000
325000
330000
335000
340000
345000
OUR OLD
36
59
5.8
32
21
4 9
12
5
7
6
Weight OUR roll cage
power train
knckle
tire
suspension
seat
steering
breake
electricals
fasteners
miscellaneous
196 KG
196
252
0
50
100
150
200
250
300
OUR OLD
3,19,290 INR
18,125
85000
11500
32000
106291
6000
9550
27000
15000
2724 6100
COST OLD
roll cage
power train
Machining cost
tire
suspension
seat
steering
breake
electricals
fasteners
miscellaneous

12. PROJECT PLAN

13. VALIDATION PLAN
Systems Description Acceptable Criteria Test Procedures Acceptable Values
Rollcage • Material AISI 4130
(Chrome moly)
• Suited for 95% Indian
male & 5% female
• Material equivalency
• Material availability
• Reliable F.O.S
• Safety
• Modeling in CREO 3.0 & Solid works 14
• Analysis in ANSYS 15.0
• Destructive testing of welded joints
• Prototyping with MILD STEEL
• F.O.S ≥ 1.5
Powertrain • CVT with H12FNR
Gear box with 1.59 to
22.45 to Gear Ratio .
• Governor spring set at hole #6.
• Powertrain guard and side
shields.
• Theoretically calculated values
• Angular alignment
• Maximum Speed
attained is 55.89
km/h
Suspension • F Double Wishbone
• R Trailing Arm
Air (Nitrogen) Shocks
(FOX FLOAT 3)
• Infinite spring index
• Max tunability
• Kinematic design in Lotus suspension analysis
• Structural Analysis in ANSYS 15.0
• Design and assembly in CREO 3.0
• Spring Rate
(at ride height)
- Front- 5.572 N/mm
- Rear- 10.737 N/mm
Steering • Rack & Pinion Type
• “Adjustable steering
ratio”
• OEM rack and pinion, wheel etc.
• Ergonomic design
• Wheel stops as per Lock-to-Lock
angle.
• Wheel alignment
• Calculation according to Ackerman’s steering
linkages
• Graphical calculations
• Turning Radius-
2.85m
Brakes • Bybre Brakes
assembly , Bosch
Master Cylinder Used
• All Wheels Should Lock at a time • Theoretical Calculations
• Practical Test
• Braking distance
within 6 times wheel
base
Electricals
& safety
• Engine Kill Switches
• Brake Lights
• CE marking
• ISI rated
• Push-to-off switches
• Electricals Ground to Engine
• Proper Routing & Insulation
• Brake Light height
and visibility

14. TEAM FORMATION
SUDHENDHU N PANDE (CAPTAIN)
KUNTAL DESHPANDE (VICE CAPTAIN)
HARSH PARMAR (DRIVER)
TIG WELDING MIG WELDING
Lathe machine UNIVERSAL DRILL M/C
STAND GRINDER SPOT WELDING
ARC welding GAS WELDING
SHAPER M/C POWER HACKSHOW
COCK FURNACE ANVIL
STAND DRILL MACHINED WOODEN LATHE
HAND GRINDER HAND DRILL
HAND CUTTER LEVER CHASE
RIGHT ANGLE TAP SET AND TUB
THREADING DIE PUNCH
RATCHET
SPANNER SET (RING AND
FIX)
MACHINE FACILITIES IN WORKSHOP
TEAM STRUCTURE AND COLLEGE FASCILITIES
FACULTY ADVISOR (2017): Prof. NIKUL PATEL
Prof. MOHIT TEACHER
ROLLCAGE
HARSHIL
VISMAY
ADITYA
ARIHANT
ANAND
POWER TRAIN
ISHAN
MAYANK
SHAILJA
KAYZAD
HARSH
DOCUMENTATION
SHAILJA
DIYANA
HARSH
STEERING
SUDHENDHU
VINIT
ABHAYSINH
PRIYANK
BRIJESH
BRAKES
BHAUMIK
ARJUN
ABHAY
ISHIT
PAWAN
MARKETING
PRIYANK
HARSH
KUNTAL
ELECTRICALS
VINIT
BHAUMIK
SUSPENSION
KUNTAL
URVESH
RUSHI
DIYANA
CHINTAN
FACULTY ADVISOR (2015): Prof. Madhav Oza