Design Presentation ROADIES. Regd. ID : National Institute of Foundry & Forge Technology, Ranchi L/O/G/O.

Transcription

1 Design Presentation ROADIES Regd. ID : National Institute of Foundry & Forge Technology, Ranchi L/O/G/O

2 TEAM ORGANIZATION TEAM CAPTAIN TEAM VICE-CAPTAIN RICHARD DOLEY AKSHAY TRIPATHI TECHNICAL MANAGEMENT UTSAV MAHTO KR. SAMBHAV Design & Analysis Fabrication Publicity Sponsorship Procurement VIKAS UTSAV ANUROOP, RAJA,SATISH RISHIKANT CHAITANYA DWIVEDI VISHAL PANDEY ABHIMANYU RAJ VARDHAN ANKIT GUPTA ASHUTOSH Roll Cage Steering Suspensions Tires & Brakes DHARMENDRA RAJAT MANAS GOND BITTU GUPTA ROHIT UJJIR HITESH GODWANI

3 ROLL CAGE DESIGN METHODOLOGY Driver-oriented Cockpit design. Light weight, Compact and simple. High Roll stiffness and structural rigidity Easy egress during mishap. Least no. of welds and members Material Carbon Steel AISI 1018 UTS 365 Mpa Carbon content 0.18% Outside dia.: Wall thickness: 25.4 mm 3.05 mm WELD JOINTS Number of weld joints Weld length = 62 = m

4 Roll Cage Analysis (Software: ANSYS 13.0) Front Impact Analysis At Speed : 60 km/hr (16.67 m/s) Impact Time : 0.1 sec Thus, Load= N on front members. Max STRESS : 174 Mpa Max DISPLACEMENT : 2.38 mm Factor of Safety: UTS/Smax = 365/174 = 2.1 Side Impact (Safe case of Side Roll over) Load: 2G loading (6180 N) on side members. Max STRESS : 69.4 Mpa Max DISPLACEMENT : 2.26 mm Factor of Safety : 365/69.4 = 5.25 Roll Over (Dynamic) Analysis Load: 2G Horizontal on side members 1G Vertical on top members. Max STRESS :136 Mpa Max DISPLACEMENT : 5.5 mm Factor of Safety : 2.68

5 Suspension: Double Wishbone Parallel SLA FRONT LOWER ARM REAR UPPER ARM SHOCK MOUNTING LOCATION: Front Rear Lower arm, centre Upper arm, inner LENGTH OF A ARMS: Front Upper arm Lower arm 312 mm 338 mm Rear Upper arm 263 mm Lower arm 287 mm ROLL CENTER HEIGHT: Front mm Rear mm

6 Steering Rack and Pinion; simple design and easy to install. 100% Ackermann geometry Target Specifications: Gear Ratio 12:1 Caster Camber (static) Toe-in King-pin Inclination 12 Scrub Radius Lock Angle 5 Positive 2 Negative 10 mm 44 mm 40 (approximately) No. of turns to steer from Extreme Left to Extreme Right Turning Radius 2.66 turns

7 Braking System Maruti 800 calipers and disc will be used Features: Hydraulic disc brakes Two independent braking circuit Equipped with SMART Turning Assistance System Two servo motor assisted valves on rear circuit. While turning left, on application of brakes will lock both front wheels and rear left wheel. Rear right wheel with drive will get moment along these 3 locked wheel hence turning would be easier. Target Specs: Pedal Ratio 6.2:1 Braking Effort 1300 N per wheel Deceleration 7.53 m/s 2 Stopping distance 21.5m (max speed 60 km/h) Assumption: Brake Efficiency = 70% Coefficient of friction =0.65 Formula used ῖ = BfwR/r Bf = Mag s = v 2 / 2gaₓ/g the

8 Power Train Briggs and Stratton Engine: 10 hp OHV Intake 20S New engine with 3800rpm Overhead Valve Design (OHV) Runs cooler and cleaner delivering more power, longer engine life and improved fuel economy Flange Coupling Torque* (ft-lbs, gross) Engine Displacement (cc) Number of Cylinders Engine Configuration Engine Technology Single Horizontal Shaft OHV Length (in) 12.3 Width (in) 15.4 Height (in) 16.4 Weight (lbs) 50.4 Bore (in) 3.12 Stroke (in) 2.44 Engine Fuel SPARK PLUG Gasoline RC12YC

9 Safety & Ergonomics Racing type 3 ways Adjustable seats, for driver comfort. 5 point harness seat belt system along with neck restraint and arm restraint Belly pan running entire length of cockpit, Roll cage foam padding and body panels will be provided Kill switches will be installed to kill the ignition in case of emergency Pivoted bumper with spring support in front of vehicle to absorb energy from collisions SAE grade brake lights will be installed and all wiring will be properly insulated and clipped. All rotating parts will be properly shielded with sheet metal. Splash shields and Drip pans will also be provided Fire extinguisher within the reach of driver will be provided Belly pan and Roll cage padding Gear indicator to enable quick gear shifts

10 Design Specifications Overall length Track width Wheel base Overall weight Engine Transmission Tires Rims Roll Cage Suspension (front and rear) Steering System Braking (front and rear) Maximum Torque Maximum Speed 2.3 m Front: 1.55 m Rear: 1.45 m 1.60 m 310 Kgs (inclusive of Driver) Briggs and Stratton 10hp OHV Mahindra Alfa(modified) 22 x 8 inches, 6 ply ATV 10 x 6 inches SAE 1018 seamless steel tubes 1 OD and 3 mm wall thickness Double Wishbone suspension (Parallel and unequal arms) Customized Centered Rack and Pinion Gear Ratio = 12:1 Hydraulic Disc brakes rpm 60 KMPH

11 2-D views

12 Final View

13 Design Validation Plan No Description Accomplishment Targets 1. Welding test Strength of welded components should be within permissible limits. 2. Ground Clearance Test Should not be less than the specified value i.e. 10 inch 3. Braking Test The vehicle should stop within safe limits and all the wheels should be locked 4 Wheel Travel Should be at least 6-7 inches (jounce rebound) 5. Straight Line Stability Should move in a straight line when steering is at neutral position. 6. Turning Radius Should be approximately equal to the calculated value. Allotted Resource Abhimanyu Yadav Ashutosh Saraswat Ankit Gupta Raja Sah Rohit Ujjir Anuroop Kulshresta Means Of Accomplishment Universal Testing machine 10 inch Spacer. To be tested on track with 2 different observers for wheels on each side. Braking distance to be measured from point of brake application to point of stop. Ruler Driving the car in neutral steering position parallel to the white strips on road. Radius will be measured using measuring tape. 7. Fuel Leak Test Should not leak fuel or fluid at any circumstances. Vishal Pandey Vehicle should be tested in various roads conditions and any case of spills to be scrutinsed. 8. Speed and acceleration test By recording the time travel while traversing a path Hitesh Godwani Obtained data shall confirm the calculated value

14 College & External Facilities MACHINING Center Lathe Universal Milling Machine Grinding Machine Drilling Machine WELDING Metal Inert Gas welding machine TIG welding machine Electric arc welding machine MANUFACTURING MACHINES CNC Milling Machine Hot Isostatic Press(HIP) Machine Rapid Prototyping Machine TESTING MACHINES Brinell Hardness testing machine(3000 kg) Universal tensile testing machine(60 tonne) EXTERNAL FACILITIES: CNC Pipe Bending. Laser Cutting (for hubs). Paint Equipment.

15 Project Plan

16 Cost Estimates Category Items Cost Frame Power Train Steel tubes, Sheet Metal, Welding supplies, roll cage padding etc Engine, transmission, shifters, chains, sprocket, couplings etc 37,200 47,000 Wheels and tires Rims & tires(4+2) 39,900 Suspension Steering Safety equipments Braking Misc Shocks, springs, A arms, uprights, hubs, spindles Rack & pinion, steering column, steering arm, steering wheel, tie rods etc Driver s suit, helmet, fire extinguisher, harness system, restraints, kill switch etc Calipers, master cylinders, servo motors, brake lines etc Travel, transportation, accommodation etc 22,000 11,600 37,500 14,500 30,000 Total 2,39,700

17 THANK YOU!!!