Post on 27-Apr-2015
description
• Team functioning.• Design methodology.• Technical speciffcations.• Roll cage & vehicle simulation.• Innovations & USP’s.• Safety features• Project marketing.• Future plan of action.
• Design & drafting.
• Fabrication.
• Marketing & cost.
Allocation of departments.
Brain storming.
Regular team meetings.
• Safety.
• Serviceability.
• Part standardisation.
• Minimum weight, sufficient strength.
• Easy access and effective controls.
• Minimum cost & simple design.
• Aesthetic value.
Technical Specifications
Single cylinder 4 stroke air cooledBore 82mm
Stroke 64mm Displacement 338ccCompression Ratio 8:1 Power 8KW
@4400rpm
Max Torque 19Nm @2800rpm
Dry Weight 30.5kg
1. Clutch2. Gear box3. Differential
Overall gear ratios• Reverse 55.08• First 31.48• Second 18.70• Third 11.40• Fourth 7.35
• PRO-E
• CATIA
• SOLID WORKS
• F.E.M DONE
• To develop a frame that conforms to the SAE standards.
• To develop a frame that is streamlined, low-weight and safe for the driver and other competitors.
• Optimize the Stress-Weight tradeoff.
• Cost effectiveness.
• Perform simulation on all Baja models.
• Analyze and Evaluate the stress distributions.
• Drivers’ safety First
• Optimize Stress Vs Weight relationship.
Five loading conditions:
1. Rollover
2. Front Bump
3. Rear Bump
4. Frontal Collision
5. Heave
Test: Frontal Collision
Loading: a uniformly distributed 4500 N force in X-direction at the front of the vehicle
Boundary Condition: Rear corner:Trans X=Y=Z=0Opp.Rear corner:Trans X=Y=0Front corner:Trans Y=0Opp.Front corner: Trans Y=Z=0
Test: Heave Loading
Loading: Engine and Driver load = (90 +270)*3= 1080 Kg
Boundary Conditions: One rear corner: X,Y & Z =0Opposite rear corner: X &Y =
0One Front Corner: Y = 0
Test: Rollover
Loading: Rollover loading
SAE NORM IS 11821
Vertical load: 7000 N
Test: Front Bump
Loading: a point force of 810 N
in the Y-direction of the front corner
node
Boundary Conditions: Rear corner:Trans X=Y=Z=0Opp.Rear corner:Trans X=Y=0Opp.Front corner: Trans Y=Z=0Other corner: Simulate the
force equal to 3 X Total Vehicle Weight = 810 N
F
Test: Rear Bump
Loading: 810 N in Y-direction of the rear corner
node
Boundary Conditions: • Front corner:Trans
X=Y=Z=0• Opposite Front corner: Trans X=Y=0• Rear corner: Trans
Y=Z=0• Other corner: Simulate
the force equal to 3 X Total Vehicle Weight = 810 N
F
Blue: Pass
Red: Failed
• Strength: Weight and Aesthetic
• The weight : 270 Kg
• Passed all the five loading cases
PROPERTY AISI 1040Density (×1000 kg/m3) 7.7-8.03
Elastic Modulus (GPa) 190-210Tensile Strength (Mpa) 615.4Yield Strength (Mpa) 375.8Impact Strength (J) 6.1Hardness (HB) 174Elongation (%) 24.7
• Central roller rack steering.
• Used customized rack & pinion (2009).
• Used RBS steering (2007).
• Removable steering wheel.
• Disc brakes in all four tires.
• X type brake lining for high reliability.
• Standard brakes and calipers.
• Individual braking system for rear tires.
• Double wishbone suspension for both front and rear.
• Independent suspension system.
• High adjustability.
•Adjustable mounting rail.
• Proper all terrain tyres.
• Smaller tyres in front, bigger tyres at the rear.
• Made for better maneuverability & high traction.
• Exhaust compatible with engine.
• Fitted with catalytic converter.
• Green vehicle.
• Safe roll cage design.
• Easy & quick exit possible.
• Removable steering wheel.
• Proper fire wall.
• Fuel tank insulated by asbestos sheets.
• The vehicle will be fitted with 2 kill switches.
• Removable steering wheel.• Individual brakes for rear tyres.• Adjustable mounting rail for
suspension.• Compact & safe roll cage.• Green vehicle.• Overall low manufacturing cost.• The safety features.
• Team sponsorship.
• Money generation.
• Custom sponsorship.
• BOSCH (KBX) ready to sponsor brakes.
• MUNJHAL SHOWA ready to sponsor shockers
• Brake pedals will be sponsored by ARJUN AUTOS.
• Talks on with Shell, Honda (H.M.S.I), Sona Steering for team sponsorship.
• Expecting a major break through very soon.
• Total project cost without registration amount Rs. 133,737
• Total project cost with registration amount Rs. 183,737
• Total project cost with registration and transport amount Rs. 218,737
• Total project cost without Engine, Transmission and registration amount but including transportation Rs. 128,737
• Total project cost without Engine, Transmission and registration amount not including transportation Rs. 93,737
• Total cost of vehicle (removing cost of driver’s accessories)
Rs. 79,237
• Total cost of vehicle (removing sponsored items)
Rs.67,237
• Total cost of vehicle (removing the items that already have)
Rs. 53,937
• So, this time we need to spend only Rs. 53000- Rs. 55000 to design and fabricate
the vehicle.
• Time management.
• Sponsorships.
• Part procurement.
• Fabrication.
• Periodic reviews.