Team Tachyons New

7/28/2019 Team Tachyons New

1/59

ACADEMY OF BUSINESS AND ENGINEERING SCIENCES

GHAZIABAD (U.P)

Proposed Aggregates for SAE BAJA-2014


2/59

To design, build and race off-road vehicles for animaginary firm which are manufacturable to withstand theharshest elements of rough terrain.

Cost Effective

The vehicle must be safe, easily transported, easilymaintained and fun to drive. It should be able to negotiate

rough terrain without damage.


3/59

CONFORMATION UNDER SAE RULES

DRIVER EXIT TIME LESS THAN 5 SECONDS

TARGET KERB WEIGHT LESS THAN 300kg

TOP SPEED OF 60 km/hr

TURNING RADIUS LESS THAN 8 FEETS

OPTIMUM GRADIENT


4/59

ORIGINALITY

INNOVATION

SAFETY

SPACIOUS COCKPIT

MANEUVERABILITY

AESTHETICALLY PLEASING


5/59

1 SKETCHING

2MODELING

DIMENSIONING OF ROLL CAGE

34

MATERIAL SELECTION

5

FINITE ELEMENT ANALYSIS

6AGGREGATES SELECTION

7SIMULATION


6/59

STEERING

BRAKES

TRANSMISSION

SUSPENSION

WHEELS AND TYRES


7/59

1. Siddharth Garkhail2. Rahul Mahajan3. Nawanit Singh Yadav4. Atin Kumar5. Amit Pandey6. Shubham Singhal7. Gaurav Kumar8. Satendra Kumar9. Shubham Kansal10. Sandeep Kumar Jha

11. Nipun Sabharwal12. Anurag Gupta13. Ashwarya Singh14. Manoranjan Pandey15. Aviral Yadav16. Rahul Kaushik17. Tushar Thakral

18. Farheen Siddiqui19. Praveen Shahi20. Manish Kumar Singh21. Sonali Acharya22. Sandeep Kumar23. Damodar

24. Deepak Singh Attri25. Monika Srivastav

DEPARTMENTAL HEADS:

DESIGNING: Siddharth ENGINE & TRANSMISSION: Anurag SUSPENSION: Nipun STEERING: Rahul BRAKES & TIRES: Satendra DOCUMENTATION: Sonali

ELECTRICAL: praveen


8/59

Material Selection:There mainly three types :1) DOM

2) CDS3)ERW

ERW ERW stands for electrical resistance welded pipe. A plate rolled tobecome a pipe and welded using electric resistance welding process.

Used for only high diameter and not as strong as DOM thus not suitablefor SAE


9/59

DOM stands for Drawn Over Mandrel . DOM is a cold drawn electric resistance welded tube with all the

flash removed prior to cold drawing.DOM tubing produces more accurate O.D. and I.D. Tolerance as

compared to others.Has high tensile and yield strength and gives clean I.D. and O.D.

surfaces.DOM are called to be seamless but they are not technically

seamless since during manufacturing process the weld line becomesnearly undetectable.

Suitable for SAE.

DOM


10/59

CDS is a cold drawn steel tube which offers uniform tolerancesenhanced machinability and increased strength and tolerances.

Superior surface finish , dimensional accuracy and excellentmicrostructure uniformity.

Also suitable for SAE.Since DOM is cheaper as compared to CDS with exactly the same

properties so we opt for DOM.

CDS

DOM OVER OTHER

The machining qualities of DOM tubing are similar to that of seamlesstubing of the same size and analysis. But, it has higher strength andexcellent machinability.

DOM is cheaper. ( INR 145 per square feet)


11/59

There are many materials that can be used, some of them are :

Carbon steelMild steelChrome molybdenum steel1018 mild steel1020 mild steel4130 chromoly

But with SAE compliance we can use mild steel and low alloy steel so thesuitable ones are 1018 , 1020 , 4130 chromoly.

ROLL CAGE MATERIALS


12/59

COMPARISONMaterial Yield

Strength(Mpa)

Modulus of elasticity(Gpa)

CarbonContent (%)

Density(g/cm3)

Wallthickness(inches)

1020 MS 165 200 0.20 7.87 0.113

1018 MS 365 205 0.28 -0.33 7.85 0.104

4130chromoly

435 205 0.30 7.85 0.083

1026 CS 415 210 0.22-0.28 7.858

Rulebook ---- ----- 0.18 ----- 0.062


13/59

4130 chromoly is more stronger than mild steel and that allowschromoly to be a thinner wall tubing.

1020MS is less expensive than 4130 chromoly but comes with thedisadvantage of more weight.

1020MS will increase the weight about 50-60 pound heavier thanthe 4130chromoly and nearly double the price.

Since in compliance with SAE we can compromise with cost but notwith weight so we must opt for 4130 chromoly.

4130 requires TIG welding .


14/59

1.1 Material usedThe material we used in our 2012 Baja vehicle is ASTM 106 , grade B ,carbon

content 0.25% and yield strength 364 MpaIts available in Ghaziabad at following shopsa. Bharat pipeb. Haryana pipe company

Other option available to us are AISI 1018, AISI 1020,AISI 4130These are available in Delhi at the following shopa. Sidhant metals


15/59


16/59

INITIAL SKETCKES :

1. 2.


17/59

3.


18/59


19/59

Praposed RollCages for baja2014


20/59

Finalized Roll Cage for SAE BAJA

2014


21/59

SIDE VIEW

TOP VIEW

FRONT VIEW


22/59

ISOMETRIC VIEW

REAR VIEW


23/59

ComparisonCOMPARISON 2012-2013 2013-2014

F.O.S (front) 3.7 1.82

F.O.S (rear) 2.54 1.07

F.O.S (side) 2.05 1.8

Front impact load: 16000 N 30000 N

Side impact load: 8000 N 15000 N

Wider cockpit for more comfortride.

Inclined SIM for the fast exit of driver.

Rear compartment modified togive more asthetic look and toprovide a utility compartment.

Raised RHO at the front. Appropriate space for ABC

mounting.2013-2014

2012-2013


24/59

FEA (front impact)

FOS=1.8


25/59

FEA (rear impact)

FOS=1.1

FEA (Sid i )


26/59

FEA (Side impact):

FOS=1.7


27/59


28/59

1. Clutch2. Gear box

3. DifferentialOverall gear ratios Reverse 55.08:1 First 31.48:1 Second 18.70:1 Third 11.40:1 Fourth 7.35:1
http://www.mahindra.com/index.asphttp://www.mahindra.com/index.asp


29/59

Why Flange Coupling??

FLANGE COUPLING

Larger torque range(25KNm 1310 KNm

Easily assembled and

dismantled Low cost Available in standard

sizes Friction losses are lesser

than belt or chain drive

BELT DRIVE

Speed ratio not constant Heat accumulation COG moves up


30/59

Why manual transmission over CVT??

MANUALTRANSMISSION

Mechanical efficiency

is better than belts Couples to engine with

a rigid clutch Better fuel economy

CVTs

Based on strength of belts or chain

Costly Noisy Transmitting motion

by friction causeswear


31/59

ENGINE:

BRIGGS & STRATTONMODEL 200000

Bore: 3.120 in (79.23 mm)Stroke: 2.438 in (61.67 mm)Spark Plug Gap: 0.030 in (0.76mm)Intake: 0.004 0.006 in (0.10-0.15 mm)Exhaust: 0.004 0.006 in (0.10-0.15 mm)


32/59

Single Cylinder Four Stroke, 305cc

Over Head Valve (OHV)Compression Ratio: 8.0 : 1Engine Ideal RPM is set to 1750 rpm

Weight: 29.10 KgsGovernor RPM: 3800 rpm

ENGINE(continued):


33/59

BRAKES:Rules require two independenthydraulic systems

DISC BRAKES WITH VENTED DISC :Advantages :

Good resistance to brake fadeBetter braking efficiencyHigh performance torqueLesser stopping distance than drum brakesLess wear and tear Good dissipation of heatLight in weight


34/59

Types Of Master cylinder

Single cylinder, dammed reservoir Pros: simple, packaging flexibilityCons: longer than dua l cylinders

Dual cylinders, overhead mountPros: shortest overall lengthCons: aesthetics

Dual cylinders, floor mountPros: elegant packagingCons: longer, may conflict withsteering components


35/59

Proposed brake assembly:

Maruti 800 disc brake assembly


36/59

STEERING

We are using rack and pinion of TATA Nano.We will customize the pinion to center position onrack.Hence, we will be able to use equal tie-rods.Ackermann steering geometry.Tie rod lengths = 12.59 inc keeping ball joint

position 1 feet from the rack

The turning radius is calculated as 3.45 m (approx)


37/59

Rack and Pinion Steering

Simplified system

Light

Ease of integration with suspension


38/59

Proposed steering for SAE BAJA 2014:

The proposed steering for our ATV will be a Four-Wheel Steering system because:

Minimum turning radius.Maneuverability increases.This will be helpful in maneuverability test andfigure of eight test .


39/59


40/59


41/59

SUSPENSION

We will be using double wishbonesuspensions in front and rear.

REASON:

We can get maximum travel by placing itat almost 90 degrees

We can arrange the values of caster &camber angle as per our requirementsSteering effort is very less as compared toMcpherson strut


42/59

We will be using MONORE

suspensions in front and TATAIndica suspensions after customization, in rear.

We will be installing a tenderspring to maximize thesuspension efficiency, that is,our vehicle will not produce

jerks on application of smallloads.


43/59

SPECIFICATIONS (FRONT): WIRE DIAMERTER : 9 mm OUTER DIAMETER : 100 mm NUMBER OF ACTIVE COILS : 8 LENGTH : 482.6 mm SPRING INDEX : 10.11 MODULUS OF RIGIDITY : 85 GPa STIFNESS : 11.56~12 N/mm


44/59

SPECIFICATIONS (REAR):TENDER SPRING:

Max. force=300 N (assumed)Stiffness=10Deflection=30 mm

No. of active coils=7Wire diameter, d=7 mmMean coil diameter, D=71mmLength of spring=84 mm

MAIN COIL SPRING:Max. force=1500 N(assumed)Stiffness=19

Deflection=75 mmNo. of active coils=5Wire diameter, d=9 mmMean coil diameter, D=90

mmLength of spring=220 mm


45/59

FRONT SUSPENSION(MONORE)

REAR SUSPENSION (INDICA)


46/59

Front Tire:Overall Diameter- 25 inchesSection Width 8.0 inches

Rear Tire:Overall Diameter- 26 inchesSection Width 10.0 inches

Rear Tire

TIRES SPECIFICATION

Front Tire

CENTER OF GRAVITY CALCULATIONS


47/59

CENTER OF GRAVITY CALCULATIONS:S.No. COMPONENT WEIGHT

(Kg)X (cm) Y(cm) Z(cm)

1. DRIVER 70 92 0 5.08

2. ENGINE 30 153 13 20.32

3. TRANSMISSION 17 153 -9 2.54

4. FUEL TANK 5 120 -25 71.14

5. HALF SHAFTS(REAR) 6 175 0 -2.54

6. ROLL CAGE 66 84 0 35.56

7. RACK 7 0 0 0

8. Front tyre 40 0 0 -22.86

9. Rear tyre 40 175 0 -22.86

10. FRONTSUSPENSION

10 0 0 20.32

11. REARSUSPENSION

16 162.3 0 30.48


48/59

NET WEIGHT OF ATV IS: 307 KG

X=((70x92)+(30x153)+(17x153)+(5x20)+(6x175)+(66x84)+(16x162.3)+(40x175))

307=100.97 ~ 101 cm

Y= ((30x13)+(17x(-9))+(5x(-25)307

=0.36 cm

Z= ((70x5.08)+(30x20.32)+(17x2.54)+(5x71.14)+(6x(-2.54))+(66x35.56)+(10x20.32)+(16x30.48)+(40x2x(-22.86))

307=8.33 cm

Considering the origin to be the center front axle.The height of COG from ground is (8.33+22.86) = 31.19cm


49/59

ELECTRICAL AND ELECTRONICS

Other Accessories:

BRAKE LIGHT-

The vehicle must be equipped with a red brake light.When the break is applied the wire get shorted, results in thecompletion of the circuit and the break light get SWITCH ON.

REVERSE ALARM and LIGHT-

The vehicle must be equipped with a reverse alarm and light.Amber colour, visible at a minimum distance of 10 meters fromvehicle.


50/59

THE BATTERY:

Battery is the main Part of the electrical system in an Automobile.

The Battery supplies current for operation of the starting motor andignition system.The Battery used in our ATV would be of the rating 12V/44 Ah.

LIGHTNING AND WIRING:

Main battery feed circuit - 44/0.012

Main charging Circuit - 23/0.012Field Circuit - 14/0.012


51/59


52/59

KILL SWITCH:

Each vehicle must be equipped with two (2)easily accessible kill switches to push off theignition and the entire electrical system of thecar.


53/59

TESTS RUN

1 2 3

RESULT

ACCELERATION TEST

BRAKE TEST

MANEUVERABILITY TEST

HILL CLIMB TEST

TURNING TEST

OFF ROAD TEST

LAP TIME TEST


54/59

Task No. Start Date Duration Task Description

Task 1 1-Mar-13 20 Selection of Team

Task 2 21-Mar-13 10 Intro. Meetings+fund collection+signing undertakings+membership forms

Task 3 1-Apr-13 10 Sketches for rollcage design

Task 4 11-Apr-13 8 Preliminary solid work modelling

Task 5 19-Apr-13 3 FEA on solid works

Task 6 22-Apr-13 5 Finalised rollcage

Task 7 11-Apr-13 7 Material Selection

Task 8 27-Apr-13 1 Preliminary presentation

Task 9 11-Jun-13 10 PVC modelling & amending rollcage on solid works + analysis on ANSYS

Task 10 21-Jun-13 5 1:5 Scale Model

Task 11 1-Apr-13 25 R&D for selection of diff. aggregates

Task 12 11-Jun-13 15 Finalising the aggregates , innovation, ppt preparation

Task 13 21-Jun-13 5 Call for Scholarship

Task 14 26-Jun-13 11 Final Presentation Completion

Task 15 6-Jul-13 10 Practice for Virtual Round

DESCRIPTION OF TASKS FOR SAE BAJA 2014(VIRTUAL PHASE)

GANTT CHART FOR SAE BAJA 2014


55/59

1-Mar-13 21-Mar-13 10-Apr-13 30-Apr-13 20-May-13 9-Jun-13 29-Jun-13 19-Jul-13 8-Aug-13

Task 1

Task 2

Task 3

Task 4

Task 5

Task 6

Task 7

Task 8

Task 9

Task 10

Task 11

Task 12

Task 13

Task 14

Task 15

GANTT CHART FOR SAE-BAJA 2014(VIRTUAL PHASE):


56/59

DESCRIPTION OF TASKS FOR SAE BAJA 2014(MANUFACTURING PHASE):

Task No. Start Date Duration Task Name

Task 1 1-Sep-13 15 Marketing & Arrival of Material

Task 2 16-Sep-13 7 Rollcage Fabrication

Task 3 18-Sep-13 5 Double A-arm manufacturing

Task 4 23-Sep-13 2 Brake cylinder , steering, rack & pinion brackets

Task 5 25-Sep-13 3 Engine mounting & suspension bracket

Task 6 23-Sep-13 2 Double A-arm mounting

Task 7 25-Sep-13 6 Double A-arm assembly & ball joint , knuckle + tire+ brake disc calliper mounting

Task 8 1-Oct-13 1 Brake cylinder assembly

Task 9 2-Oct-13 4 Steering rack assembly

Task 10 6-Oct-13 5 Steering mounting and ackermann config.

Task 11 11-Oct-13 3 Shocker assembly mountingTask 12 14-Oct-13 3 Engine + transmission mounting

Task 13 17-Oct-13 1 Lubrication

Task 14 18-Oct-13 7 Vehicle testing & adjustment

Task 15 22-Oct-13 7 Electric mechanism mounting

Task 16 29-Oct-13 3 Sheet metal cutting and riveting

Task 17 1-Nov-13 7 Final testing and adjustmentTask 18 8-Nov-13 2 Paint

GANTT CHART FOR SAE-BAJA 2014


57/59

(MANUFACTURING PHASE):


58/59


59/59

Team Tachyons New

Documents

Transcript of Team Tachyons New