Dr. M.G.R.

EDUCATIONAL AND RESEARCH INSTITUTE UNIVERSITY

(Decl. Under Sec. 3 of UGC Act 1956)

VIRTUAL SUPRA SAE INDIA 2010 TEAM GARUDA ULTIMATE

The SUPRA SAEINDIA 2011 competition challenges teams of university undergraduate and graduate students to conceive, design, fabricate and compete with their own small formula style autocross racing cars. For the purpose of this competition , the students need to assume that a manufacturing firm has engaged them to design, fabricate and demonstrate a prototype car for evaluation of the same as a product ready for production. The vehicle should meet all the safety parameters as per the rule book. The use of Maruti 800 BS 3 engine is mandatory. The vehicle must be open-wheeled and open cockpit ( a formula style body). Minimum wheelbase allowed is 60 inches. Vehicle track must be no less than 75%of the larger track. Minimum ground clearance- 1 inch Vehicle must have inspection holes and all suspension points should be visible. Braking and steer-by wire is prohibited. Total usable wheel travel of at least 2 inches . Allowable total steering system free play is limited to 7 degrees. Stopping distance must be one and half distance of the vehicle length when driven at a speed of 40 Kmph

 Real time prototyping

Material used-PVC pipes

Dimensioning done in accordance with the tallest driver Parameters of the rule book considered

PRO-E was exercised to design the 3-D model of the roll cage

SPECIFICATION: Main hoop and front hoop OD 40mmX2mm wall thickness Side impact and bulkhead OD 25.4mmX1.65mm wall thickness Roll hoop bracing and driver restraint harness OD 25mmX1.75mm wall thickness Front bulkhead support OD 25.4mmX1.25mm wall thickness Maximum triangulation provided Side impact member attached at a height of 350mm. Maximum round corners for stress redistribution
Material specification: Material used- SAE 4130 Yield strength- 435 Mpa Youngs Modulus- 205 Gpa Ultimate strength- 670 Mpa Poissons ratio- 0.29 Density- 7850 kg/m^3

Front impact: Force applied-12000N Points constrained- all degrees of freedom of rear most tubing were constrained FOS- 6.5

fig1. Front impact

Side impact:-

Force applied-12000N to side impact member Points constrained- SIM was constrained FOS- 5.1
Fig2. Side impact

Torsional stiffness: Force applied-1000N at the end of test rod Deflection observed- 33mm Torsional stiffness- 705.33 Nm/deg
fig4. Torsional stiffness

Static loading: Load due to drivers weight- 686N Engine and transmission- 2000N Constraints- wishbone connecting point FOS- 16
fig5. Static loading

1. Main hoop: Size- 65X92cm height is kept low to minimize air drag Bracing in compliance with the rule book

2. Front hoop: Size- 40X50cm Below the drivers eye line Bracing in compliance with the rule book

3.Front bulkhead: Size- 32X30cm Minimum frontal area As per the suspension geometry

1. Fully independent outboard suspension, unequal length, non-parallel, double A- arm design 2. Inference from the drawing: Trackwidth- 1200/1120mm Wheel base- 1710mm Ground clearance- 76.2mm Roll centre- 5/9mm Scrub radius- 16mm KPI- 7/6 deg Camber- -2/0 deg

3. Alternatives considered: Mc-Pherson strut Swing axle suspension

1. Mc-pherson 2. Swing axle

 Coil-over shocks: preferred over gas shocks due its superior ability to respond after impact Has a high damping ratio

Correct valving and spring rate

Easily available and fits in constraining parameters.

Type :Rack and pinion Alternatives considered: Pitman arm steering Recirculating ball steering Steering specification: custom made rack and pinion material- mild steel central steering for quicker response steering angle- 280 to 40 steering ratio- 5:1 lock-to- lock ratio- 1.25 turns turning radius- 3m

 Hydraulically operated braking system Disc brakes on all four wheels

Independent front and rear brake circuit Proportionating valve used to adjust the brake pressure difference between front and rear Maruti 800 master cylinder
Brake disc size-220m Front circuit pressure=1.533 N/mm2 Rear circuit pressure=1.839 N/mm2

Stopping distance=2.85 m
Master cylinder size (diameter) Front =21.06 mm Rear =19.22mm

Tire specification:185/60 R-13 Rim specification:Alloy wheel rims 13 X 6 ET-30 Hub:custom made

Disc rotor:220mm (OD) Upright:custom made

HUB DESIGN: custom made hubs

material used:- SAE 4140 light weight to reduce unsprung mass and to ensure vehicle stability provisions for brake disc mounting two bearings in each hub for better stability HUB ANALYSIS: constraints- all DOF rim attachment positions were constrained force applied- 10500N FOS- 6.5-8

Static nodal stress: Force applied on upper and lower wishbone mounting point-450N each Bearing hole constrained

Static nodal stress

Static displacement: Force applied on upper and lower wishbone mounting point-450N each Bearing hole constrained

Static displacement

Engine specification: Type- M800 BSIII MPI engine

Swept volume- 796cc Maximum power- 26 Kw @ 5000rpm Maximum torque- 59 Nm @ 2500rpm Type of fuel used- gasoline Compression ratio- 8.8

Transmission:Type- manual Clutch type- dry, single plate No. of gears- 4 forward, 1 reverse GEAR GEAR RATIO OVERALL RATIO 1st 3.583 15.586 2nd 2.166 9.422 3rd 1.333 5.798 4th 0.900 3.915 reverse 3.363 14.629 Differential type- straight bevel gear Final drive ratio- 4.350

GENERAL SPECIFICATION: Wheelbase-1710mm Overall height-996.2mm Track width-1200/1120mm Ride height-76.2mm Target weight-360kg Maximum speed-110kmph DRIVE TRAIN SPECIFICATION: Direct coupling Transmission-4 FWD + 1 REV CHASSIS SPECIFICATION Material-SAE4130 Total weight-41kg SUSPENSION SPECIFICATION: Type-LSA (front and rear) Travel-2.2/2.5 inches Camber- -2/0 deg Castor- +4/+3 deg STEERING SPECIFICATION: Lock-to-lock-1.25 turns Steer angle-28-40 deg Steering ratio-5:1 BRAKE SPECIFICATION: Type- 220mm disc brake (front and rear) Dual tandem master cylinder

Today, necessity is more of a mother of INNOVATION than INVENTION

Concentrated towards building a SIMPLE, highly PERFORMANCE oriented, efficient and robust racing car fuelled to scorch the tracks.

PRINCIPLE CONCERNING MULTIFUNCTIONAL DEVICES: The fewer functions any machine is required to perform, the more perfectly it can perform those functions. SIMPLE, SPEEDY, DURABLE, LIGHT WEIGHT AND ECONOMICAL VEHICLE.

Various parts shall be checked by the following methods: CHASSIS: Real time prototyping will be done to test the key points for strength. SUSPENSION: has been analyzed using SusProg3D and deflection in shocks will be analyzed using spring test. BRAKING: Chassis Dynamometer. STEERING: Ground testing. ELECTRICAL: Ground testing.

Note:- All this will be done before running the actual drive cycle tests, by driving the vehicle around on MMST TRACK and at various speeds.

 Maximum speed- 120kmph Acceleration- 3.2 m/s^2 Stopping distance- 3m (@60kmph) Minimum turning radius- 3.5m

Ground clearance- 3 inch

Total vehicle weight- 350kg

Estimated cost of vehicle-Rs.3,50,000 Oil India Limited (sponsorship)- Rs. 50,000 College funds- Rs. 2,00,000 Personal contributions- Rs.75,000 (5,000 each) Balance- Rs. 25,000**

**Remaining amount yet to managed.

The team is planning on using the college machine shop for various manufacturing needs.

SERVICES AVAILED FROM OUTSIDE

TIG- welding for chassis CNC machining for hub and upright

Faculty advisor-X. CHARLES

S.No
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

NAME
Sandip Kumar Pradeep Kumar Maurya Rubina Mahtab Khan Raj Kishore Eshan Sett Prateek Singh Raju Das Sabir Fariz Hussain Shriram Jhawar Gopi Uttakaran Shahnawaz Hussain Ashish Abhishek Ashutosh Kumar Abhishek Singh Dhiraj

BRANCH
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical ECE ECE CSE ETC

INCHARGE
Team captain, Design engineer Technical head, power transmission Spokesperson, chassis and suspension Structural analysis, steering Co-spokesperson, Chief presenter, Marketing Fabrication head, Technician, Driver Braking system Structural analysis, steering Marketing and sponsorship Structural analysis and marketing Cooling system Software solutions, Electronics Electronics Software solutions, Co-driver Co-driver

SUPRA SAEINDIA 2011Main Rule Book Milliken & Milliken, Race Car Vehicle Dynamics, Warrendale, PA, SAE Inc. Thomas D. Gillespie, Fundamentals of Vehicle Dynamics, Warrendale, PA, SAE Inc. Carroll Smith, Tune to win, Fallbrook, CA, Aero Publishers Inc. http://www.fsae.com/ http://www.f1technical.net/ <http://www.howstuffworks.com