BIRLA INSTITUTE OF TECHNOLOGY SRIJAN

FORMULA SAE ITALY 2013 - PROJECT REPORT

1 | P a g e

BEGINNING: WHY FSAE ITALY

The answer to this question can be derived

from one of the primary motive of Team

SRIJAN i.e. to learn and grow.

After its formal formation and its participation

in an International competition in the year

2007 in Silverstone U.K, the team collapsed

and there was no substantial activity till the

year 2010. In that year the team was revived

and a car was fabricated to participate in a

national competition, SUPRA SAE 2011 which

was held in Chennai. The team took valuable

lessons from this endeavor and participated

for the second continuous year in SUPRA SAE 2012 held in Buddh International Circuit, Noida.

The 2012 car was built with lot of conviction, dedication and hardwork. Scientifically designed and

manufactured, it was a sincere and concentrated effort and was truly a Team’s car.

But the manner, in which the entire Noida event

was conducted and judged, barely had any scope of

learning. Without any moral principle governing the

event, it was conducted just for the sake of it. The

management was next to none, the judges were

inexperienced and the judgment was biased.

Moreover, it was really disheartening for us that we

got no appreciation for our technical design and

immaculate execution especially when we had the

lightest tubular space frame in the competition.

One thing was quite clear from our 2012 calendar that Indian Formula Student competition had a

lot to catch up to be at par with its Internal version: Formula Society of Automotive Engineers

(FSAE).

2 | P a g e

Hence, in order to learn and grow, be judged by experienced well informed judges and industry

experts, to experience the International competition level and our standing relative to it, we chose

to participate in FSAE.

We came to the conclusion that in order to design and manufacture a car suitable for an

International competition, we need at least a year’s time. As a result, out of the numerous

countries in which FSAE competitions are conducted, we chose ITALY as the event dates gave us

just the right amount of time.

Hence, we decided to participate in FSAE ITALY.

TEAM FORMATION

After the 2011 competition, most of the team members didn’t continue. So for the 2012, National

event a new team was formed which formed the core team committee for the 2013 event.

The SUPRA SAE 2012, taught us a lot of things that needed to improve with regards to the team

management and its structure. Claude Roulle, an eminent FSAE judge in one his numerous video

lectures had emphasized the importance of ‘Having an A class team with a C class car’ for first year

participants. Various forums on FSAE also discussed the importance of having quality team.

Based on these learning’s, a lot of stress was laid on having a proper team structure. Sub teams

were formed with clear cut aims. And above all, it was decided that the objective would be to build

a reliable and sturdy car that would be able to clear the technical inspection and the dynamic

events. The performance parameter was given the back seat.

For the team to benefit and learn from an event, it is important that the team continues year on

year with the majority of its members. Hence, the 2013 team had 2 senior members from 2009

Batch, 5 members from 2010 Batch, 15 members from 2011 Batch and various interns from 2012

Batch. Various written tests and interviews were conducted to select the 2012 Batch interns as well

as some members from the 2011 Batch.

Apart from having a sound technical team the importance of having an efficient management team

was also recognized and efforts were made to select people who would especially be in team for its

management. This team had various functions to perform. Maintain relations with the past

3 | P a g e

sponsors, find new sponsors and fund raising opportunities, maintain and update the site and the

team’s Facebook page etc.

For the first time, a management team was formed.

Thus, the final team had 17 members in the technical team and 5 members in the management

team.

TEAM’s APPROACH

The objective was clear from the beginning: ‘To build a simple and reliable car that could clear the

technical inspection as well as the dynamic events’. From our previous endeavor, one thing was

clearly evident that the team should have suitable sufficient testing time to iron out any flaws

before the event itself.

As a result, we refrained ourselves from focusing too much on the performance factor and did not

indulge in experimenting with new technological systems. Instead, we concentrated on improving

our manufacturing and designing of components that are easy to machine and assemble.

To gauge the progress of the team as well as decide the course of action, frequent team meetings

were conducted. At least two technical meetings and one management meeting was conducted

every week so that depending on the teams progress and requirement, required steps could be

undertaken.

The team had the Captain, Vice-Captain and the Team Manager who were responsible for leading

the team, handing out responsibilities and periodically checking the progress. Various sub teams

had their individual heads that would take final decisions on behalf of their team and report directly

to the captain.

We also realized that to have more and more ignited minds in our team, we need to create a

culture, understanding and passion for automobiles. For this, we conducted various workshops on

basic and advanced automotive principles. We regularly update our Facebook page with the latest

automotive news and technology.

4 | P a g e

Each sub-team was asked to prepare an ‘IF-ELSE OBJECTIVE’ sheet. Based on the end objective,

each sub team has its own requirements. But depending on the prevailing condition, financial

status, time, these requirements get modified and hence the above sheet. Its purpose was to

indicate the team to change the plan of action if a certain short term objective could not be

achieved due to any factor.

The interns were regularly asked to give technical presentations in front of the entire team so that

they are aware of the various systems, team’s technical requirements and simultaneously improve

their speaking and presentation skills.

Hence, a scientific and exhaustive approach was followed and is still in progress to achieve our

primary aim of having an A CLASS TEAM.

THE FINAL CAR DESIGN

ENGINE AND POWERTRAIN: The air intake system of the ROYAL ENFIELD 500cc EFI engine was

completely redesigned using RICARDO ENGINE

SIMULATION software so as to negate the power

loss as a result of a 20mm restrictor which was

purchased from AT THROTTLE BODY.

The EXHAUST SYSTEM was completely based on

manual calculations and was constructed in

house.

QUAIFE’s LIMITED SLIP DIFFERTIAL was used

along with the HALF SHAFTS, CV JOINTS and SPROCKET from TAYLOR RACE ENGINEERING to

power the wheels. The SPROCKET size was determined using the manual calculations and

OPTIMUM LAP SOFTWARE.

VEHICLE DYNAMICS: TTX OHLIN DAMPERS were used along

with machined ALUMINIUM BELLCRAKS, UPRIGHT and HUBS.

All the aluminum components were designed using

SOLIDWORKS SOFTWARE.

5 | P a g e

OPTIMUM K software was used to determine the suspension hard points for setting up the A –

ARMS.

FRAME and ERGONOMICS: An exhaustively triangulated and rigid frame, constructed of SAE 1018

steel was designed using SOLIDWORKS SOFTWARE.

A combination of MIG WELDING and ARC WELDING

was done by the team itself to build the frame.

The manufacturing of the frame was done using

machined fixtures made from MDF Board. This

allowed us to fabricate a frame with great accuracy

The driver’s seat was also manufactured in-house

using FIBRE REINFORCED PLASTIC.

BRAKES: TILTON BRAKE PEDAL assembly and MASTER CYLINDERS along with WILWOOD CALIPERS

and TVS FLAME BRAKE ROTORS were used. All the brake calculations were done manually and an

excel sheet was prepared for determining the required brake pressure.

STEERING: The steering system was designed for 100% Ackerman Geometry using SOLIDWORKS

SOFTWARE. All the calculations such as reduction in bump steer and steering effort were done

manually.

ELECTRONICS: The wiring for all electronic components of the car was done in the workshop itself.

WHEELS and TIRES: Custom made, lightweight ALUMINIUM FORMRACE wheels were used along

with HOOSIER SLICK TIRES.

6 | P a g e

BODY: An aerodynamic body was designed using SOLIDWORKS and was constructed from FIBRE

REINFORCED PLASTIC.

PROBLEMS FACED:

The toughest challenge was to gather sufficient funds for meeting our project budget which was

around 14 Lakhs.

In the month of January 2013, an amount of ` 1.12 Lakhs was paid for team’s registration. For this,

the members contributed from their own pocket. Our team was promised a substantial

contribution during the Golden Jubilee meet of the 1962 Batch, held in the month of December

2012. But due to some misunderstanding and lack of communication between the alumni, we

didn’t receive any funds till late May 2013.

During this period i.e from September 2012 – May 2013, team members were deeply engrossed to

gather funds so that this project could remain afloat. Hence, a lot of useful time was wasted in

these sponsorship efforts which could otherwise have gone into design improvisation.

Secondly, this delayed funding, didn’t allow us to order some important components. This

procurement delay hampered our manufacturing, severely. We could have started our fabrication

work much earlier and would have had sufficient testing time had we received our promised funds

a bit earlier.

It was only with the help Mr B.B Pant, our Training and Placement Department Head and our

sincere and persistent efforts that we were able to convince our alumni that this project was

indeed worthy of their attention. Only in June 2013, did we start receiving funds.

After we started ordering our components upon getting the required funds, we were faced with

some bizarre and unexplainable situations. We could not order steel tubes from our chosen vendor

in Mumbai due to an unforeseen trader’s strike. The courier service that transported our tubes

from our Chandigarh vendor, refused to deliver it to the Bangalore based factory where the tubes

were to be laser cut, even after reaching there. It was due to some receipt fault on the part of the

vendor. After the tubes got cut in Bangalore, they were air couriered to us by that factory in two

boxes. One box became untraceable during the transit and was delivered to us at a very later stage.

7 | P a g e

We ordered our driveline components from a U.S.A based company. Upon receiving the package

we found it to be torn at ends and some components were missing. Some aluminum components

that were CNC machined were damaged beyond repair as they were incorrectly machined. It was

all due to the inexperience of the Production Head at the Dumka tool room.

But, like the many odds that we faced in the past, we did survive this time also due to our sheer

perseverance and tremendous support from our faculty advisor, Dr Jeeoot Singh.

It would have been almost impossible for us to accomplish this feat had Dr Jeeoot Singh not been

our Faculty Incharge. He ensured that the college authorities pay heed to our requirements and

communicated on our behalf. It was because of him that we got the college to fund us with ` 2.00

Lakhs just days before the event.

At the same time, we got strength and support from Mr Sanjay Khemkha, owner of Pensol

Industries and Mr Atul Prasad alumnus from the 2006 Batch. Their financial support at such a

crucial juncture helped this project to stay afloat.

Inspite of all the difficulties faced, we were able to manufacture our car, BMR-051 within time and

were able to ship it successfully. However, due to a delayed start, our manufacturing suffered

severely and we had only a month’s time to fabricate a running car from scratch. As a result, we

could not test the car to our expectations.

DETAILED REPORT ON FUNDS:

Attached with the report is a detailed listing of how the funds were obtained and where were they

utilized.

SPONSORSHIP AMOUNT FOR TEAM SRIJAN – FSAE ITALY 2013

1. From college

Total Amount ` 2,00,000

8 | P a g e

2. From Sponsors:

SL. NO. NAME OF THE SPONSOR

AMOUNT SPONSORED

REMARKS

1. Central Coalfields Limited ` 50,000/- Release order received. Payment pending.

2. Vasundhra Homes ` 50,001/- Payment received through cheque no. 709588.

3. Jharkhand Small Industries Association (JSIA)

` 25,000/- Payment by cheque.

4. Indian Oil-Servo ` 25,000/- Payment received through cheque no. 02025506.

5. USA Jockey ` 10,000/- Payment by cash.

6 S G Enterprises ` 25,000/- Payment received via Cheque

7. Pensol Lubricants ` 50,000/- Payment received via Cheque

TOTAL ` 2,35,001/-

3. From Alumni:

SL. NO. NAME OF THE ALUMNI

AMOUNT SPONSORED

REMARKS

1. Mr. S. N. Agarwal ` 3,50,000/- Payment received through TnP

2. Mr. Abhinav Omar ` 5,500/- Payment through NEFT on 03/04/2013 and 28/05/2013

3. Mr. Kaushlesh Maheshwari ` 5,000/- Payment through NEFT on 06/02/2013.

4. Mr. Sidharth Malik ` 10,000/- Payment through NEFT on 07/03/2013.

5. Mr. R. N. Vyas ` 10,000/- Payment through cash.

6. Mr. Vishal Gupta ` 22,000/- Payment through NEFT on 19/03/2013, 08/04/2013, 01/05/2013.

9 | P a g e

7. Mr. S G Sureka ` 1,75,000/- Payment received through TnP

8. Mr. G K Gupta ` 35,000/- Payment received through TnP

9. Mr. Samir Kumar Sadhu ` 35,000/- Payment received through TnP

10. Mr. Madan Agarwal ` 98,000/- Payment received through TnP

11. Mr. Prakash Sacheti ` 50,000/- Received in SAE Account

12. Mr. D Hada ` 35,000/- Payment received through TnP

13. Mr. R P Jain ` 35,000/- Payment received through TnP

14. Mr. Vishal Gupta ` 10,000/- Payment received by NEFT

15. Mr. Atul Prasad ` 50,000/- Payment received by NEFT

TOTAL ` 9,25,000/-

4. From Ignite intent (Crowd Funding)

Total Amount Collected ` 8,000/-

Total Sponsorship amount = ` 2,00,000 + ` 2,35,001 + ` 9,25,000 + ` 8,000

= ` 13,68,001

DEPARTMENTAL BUDGET

S.NO. DEPARTMENT COMPONENT COST (MARKET ))COST)

1 Vehicle Dynamics Aluminum ` 70,000 Wet tires ` 20,000

Machining ` 1,50,000

Bearing ` 10,000

Damper Rebuilding ` 40,000

2 Engine Royal Enfield 500cc ` 1,00,000

Throttle Body ` 40,000

Exhaust ` 4,000

10 | P a g e

Aluminum ` 1,000

3 Steering Rack ` 17,000

U-Joint ` 5,500

Quick Release ` 4,500

4 Brakes Caliper ` 10, 500

Fittings and Lines ` 9,500

Rebuild Kit ` 2,000

5 Drivetrain Differential, Sprocket & Chain

` 1,62,000

6 Chassis Tubes ` 11,000

TIG Equipments ` 6,000

Fixtures ` 30,000

7 Safety Equipment Driver Suit ` 35,000

Shoes ` 4,000

Balaclava ` 2,700

Neck Support ` 1,700

Arm Restraint ` 1,700

8 Electrical & Electronics ECU ` 20,000 Wiring and taping ` 5,000

9 Power tools ` 15,000

10 Bodyworks ` 30,000

11 Management Brochures ` 10,000

Flex, Newsletters ` 10,000

TOTAL ` 8,28,100

TOTAL COST= Component’s market cost + Custom on Import (30%) + Component Shipping Cost

= ` 8,28,100+ ` 85,830+ ` 55,000= ` 9,68,930

MANUFACTURING COST SL. NO COMPONENT COST

11 | P a g e

1 Uprights ` 50,000

2 Hubs ` 50,000

3 Wishbone Inserts ` 24,000

4 Wishbone clevis ` 10,000

5 Welding ` 5,000

6 Cutting Blades ` 10,000

7 Fasteners ` 5,000

8 Tube Bending ` 10,000

9 Pedal Assembly ` 20,000

10 Bellcrank ` 16,000

Total ` 2,00,000

CAR FABRICATION COST Car Fabrication cost = Departmental Cost + Manufacturing Cost = ` 9,68,930 + ` 2,00,000 = ` 11,68,930

TEAM CONTRIBUTION

S. No. Contribution Purpose

1 ` 200x 24= ` 4,800 For initial brochures, reports, and flyers printing.

2 ` 4,750x 24= ` 1,14,000 For FSAE Italy 2013 event registration.

3 ` 4,200x 24= ` 1,00,800 For purchase of engine. A total sum of ` 1,00,000

was paid.

TOTAL ` 2,19,600/-

12 | P a g e

CAR SHIPPING, AND MEMBERS TRAVELLING AND

ACCOMODATION COST

REMARKS FROM

DESTINATION COST

1. Car Flight Ranchi Varano De Melegari, Italy

` 3,00,000

Ship Varano De Melegari, Italy

Ranchi, India ` 1,48,000

TOTAL ` 4,48,000

2. Members Train Ranchi New Delhi 500x 11= `5,500 a) Travelling Flight New Delhi Milan 21,000x 11=

`2,31,000 Miscellaneous

cost in Italy 10,000x11=

`1,10,000

Flight Milan New Delhi 21,000x 11= `2,31,000

Train New Delhi Ranchi 500x 11= `5,500

b) Accommodation Camping 4,500x11=

`49,500

TOTAL ` 6,32,500/-

SUMMARY

REMARKS AMOUNT

Car Fabrication Cost `11,68,930

13 | P a g e

Car Shipping Cost ` 4,48,000

Travelling and Accommodation ` 6,32,000

TOTAL EXPENDITURE ` 22,48,930

Sponsorship amount ` 13,68,001

Team Contribution ` 2,19,600

TOTAL ` 15,87,601

*Travelling and accommodation cost was borne by the team

AMOUNT REQUIRED = Sponsorship collected + Team contribution for engine - Car Fabrication Cost - Car shipping cost = ` 13,68,001 + ` 1,00,000 - ` 11,68,930 - ` 4,48,000 = ` 1,48,929 (Deficit)

The car is currently in transit from Italy to India via sea route. ` 1,47,629 is the amount still to be paid to the Logistics company for the return of the car.

RESULTS

Team SRIJAN secured 38th Position amongst the 55 teams from all over the world.

We also bagged 21st Position in cost analysis and our engineering design was rated as the 2nd best

from a total of 8 teams that had participated from India. We were succeeded by Vellore Institute of

14 | P a g e

Technology, Chennai, which were participating in this event for the 4th consecutive year and were

preceded by IIT Kanpur who was also participating in this event for the first time.

The official result is attached with this report.

Official results can be referred on - http://www.ata.it/it/formulaata/view/20/formula-sae-italy-

formula-electric-italy-2013/content/272/results/

15 | P a g e

THE PATH AHEAD

Soon after the event, detailed meetings were conducted on our performance on the event site and

the future course of action. It was discussed in great detail the mistakes that were made and how

should they be rectified. We also extolled ourselves over our achievement of having competed in

the International arena after a hiatus of 6 years.

Out of discussions, one thing was clearly evident that we need more time to raise funds,

satisfactorily, complete the manufacturing and test the car to our desired levels. So we are aiming

for an event that would give us more than a year’s time for achieving all the above milestones.

Secondly, in order to achieve podium finish like success, we need to have a team with extremely

sound technical knowledge. Hence, various decisions were taken as to how the team should be lead

from now on and how the members can develop and hone their technical knowledge and skill.

It was decided that the strength of the management team should be increased. It is done so as to

reduce the burden on rest of the members and at the same time have a proper team management.

Reaching at this level there is no looking back. The team is highly motivated and

wants to achieve more. The level of knowledge and

understanding of the event has increased over the years. The

team has now a strong technical support from its past members

(since 2k7 batch) placed in good industries who share their

practical knowledge regarding manufacturing and designing

with the team. With all the growing experience and support

from all corners and motivations, the team is determined to

participate at FSAE Australasia 2014 to be held in the month of December at

Melbourne.

16 | P a g e

SPECIAL THANKS TO.. Srijan would like to thank few people without whose support; this project wouldn’t be such a success.

ALUMNI Mr. S. N. Agarwal

Mr. S G Sureka

Mr. G K Gupta

Mr. Samir Kumar Sadhu

Mr. Madan Agarwal

Mr. Prakash Sacheti

Mr. D Hada

Mr. R P Jain

Mr. Abhinav Omar

Mr. Kaushlesh Maheshwari

Mr. Sidharth Malik

Mr. R. N. Vyas

Mr. Vishal Gupta (2k11 passout)

Mr. Vishal Gupta (an alumnus of Srijan)

Mr. Atul Prasad

COLLEGE AUTHORITIES

Dr. P.K. Barhai – Honorable Vice Chancellor, BIT Mesra

Mr. B.B.Pant - Dean External Relations & Coordination

Dr. Arbind Kumar – Head of the Department, Mechanical Engg

Dr. B.K.Singh – Head of the Department, Production Engg

Dr. Jeeoot Singh – Faculty Advisor, Team Srijan

Dr. Vinay Sharma – Dean Students Welfare

Mrs. Archana Mukherjee – Dy. Finance Officer

1962 Batch

17 | P a g e

SPONSORS AND SUPPORTERS

18 | P a g e

19 | P a g e

CONTACTS

Gaurav Sinha Diwakar Harsh Captain Vice Captain 8986682423 9939612494 meetme.gauravsinha@gmail.com divakar.harsh@gmail.com Saket Kumar Chief Engineer 9431104316 saketf2004@gmail.com

Team's website - teamsrijan.bitmesra.ac.in

Team's E-mail ID- teamsrijan@bitmesra.ac.in