Documente Academic
Documente Profesional
Documente Cultură
Market Survey
Data Assumption
Design Calculation
Virtual Design
1 4 420kg 58
FEA
12.
13. 14
Maximum speed
Ground Clearance Tyre dimensions
60kmph
-
54.5kmph
12.5 25x8x12
Completion
Roll Cage
All the members of the roll cage are made of SAE 4130 steel with OD 1 and wall thickness of .118 (3mm).
PROPERTIES OF MATERIAL:
Material :SAE 4130 Yield strength :600 N/mm2 Carbon composition :0.3%C(>0.18%C) The total weight of the roll cage is estimated to be 62kg. Total number of weld joints is 56 Maximum number of welds at a point is 2
Roll Cage
TEST DETAILS
Max Stress(N/mm2)
RESULTS
224.332
STRESS ANALYSIS
DISPLACEMENT
FRONT Load Applied(N) 20,000 IMPACT TEST Max Deflection(mm) 1.50883 FOS Max Stress(N/mm2) 2.7 296.421
Max Stress(N/mm2)
284.399
SIDE Load Applied(N) 13,000 IMPACT TEST Max Deflection(mm) 4.967 FOS 2.2
Roll Cage
TEST DETAILS Max Stress(N/mm2) Load Applied(N) Max Deflection(mm) FOS BUMP TEST Max Stress(N/mm2) Load Applied(N) Max Deflection(mm) FOS RESULTS 328.304 9,000 15.2842 2 313.525 5,000 12.2493 2 STRESS ANALYSIS DISPLACEMENT
ROLL TEST
100 % Ackermanns steering Proposed track width = 54 Proposed wheel base = 58 Type of steering : Rack and pinion Maximum Angular travel of steering wheel : 540o Tie rod length = 9.889 Steering effort = 20 N
Parameter
i o Steering ratio Turning radius
Crimson Thrusters
37o 26o 15 : 1 3.133 m
Maruti 800
37o 32o 17 :1 4.4 m
Target
Disc Brake 4:1 19.05 42mm 230mm 3296.16 N 14.33m 0.8g
Omni
Disc Brake
4:1
19.05mm 42mm 230mm 4239.38 N 11.145 m
7o 1o 37o
26o
3.133m
0.925g
1.028g
OEM Selected: Maruthi OMNIs Braking System Weight Transferred: 208.43N Dynamic load acting on front during braking: 2848.45 N Dynamic load acting on rear during braking: 1271.74 N
322.63mm 231.71mm
208.8396mm 13.281o
540 mm 58.55mm
1.413o
Drive Train
The power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way Gear Final Gear Ratio 31.48 18.70 11.40 7.35 55.08 Max Vehicle Speed (Kmph) 12.7 21.4 35.11 54.45 7.27 Max Tractive Effort (N) 2119.32 1258.94 767.48 494.82 3708.14 Final Gear Ratio 55.08 32.72 19.95 13.40 31.48 Max Vehicle Speed (Kmph) 7.27 12.23 20.06 29.87 12.71 Max Tractive Effort (N) 3708.14 2202.80 1343.09 902.13 2119.32 Stub axle Engine working range (M) = 1750rpm3800rpm Recommended maximum power (PM) = 6.7 KW at 3800rpm To calculate power performance function Pe = P1 e + P2 e2- P3 e3 P1 = PM/ M P1 = 16.8455 /s P2 = PM/ M2 P2 = .04235 /s P3 = PM/ M3 P3 = 1.064 E -4 /s Therefor power performance function is Pe = 1608455 e + 0.04235 e2 1.064 E-4 e3 Drive shaft Engine
First Gear Second Gear Third Gear Fourth Gear Reverse Gear
Gearbox
Wheels
Electrical Circuit
20
79.48 53
Plan and Analysis Methodology FEA : Front Impact Test Side Impact Test Rear Impact Test Roll over 1. ADAMS shall be used to determine the performance of the suspension. 2. Load will be applied on the vehicle in dynamic and static conditions to test the performance of the suspension. The system that gives the required turning radius and the least steering effect will be selected. The system that gives stopping distance closest to 11.14 m and best suitable will be selected. To select the required gear ratio, which gives torque and speed. To design the kill switch and the various circuitry Result Achieved Below yield stress Below yield stress Below yield stress Below yield stress Achieved
Suspension
Steering
To design a steering mechanism which satisfies Ackermanns mechanism and also provide self centering effect and avoids nervousness. To design a braking system which provides comfortable stop at a distance of 14.3m To increase the torque and speed of the vehicle to meet the demands of the hill climbing test. To provide fool proof lighting and sound circuits
Achieved
INNOVATIONS:
Fly ash incorporation in brakes Piezo Electric power generation Roll cage diameter optimization
Back Right Brake Back Left Brake Front Right Brake Front Left Brake Back Right Tyre Back Left Tyre Front Right Tyre
(1780,158,-1820) (306,367,-430)
(306,367,-1600) (1790,337,-585) (1790,337,-1520) (1730,132,-1090) (1730,132,-981) (173,132,-878)
20.246 1.2985
1.2985 .5234 .5234 .586 .586 .586
3
4 5 6 7 8 9 10 11 12 13
Harish
Harikrishnan Arun Benraja Madumitha Sahithya Sabari Gireesh Pawan Kumar Sai Vishnu Gowri Shanker Dhivaker Mohammed Zaid
Inspection / Machinist
Co-Driver / machinist Electrician Design Machinist / Steering Design / Welding Inspection / Machinist Machinist / Administration Design / Welding Machinist / Driver Stocker / Machinist
14
15 16 17 18 19 20 21 22 23 24
Manikandan
Mahendran Mohammed Mudassir Hariharan Manoj Somoosay Varun Vaisikan Rahul Dharmarajan Vaishnavi Srinivasan Soorya
Inspection / machinist
Machinist Machinist / Stocker Machinist / Stocker Machinist / Steering Inspection / Stocker Electrician Design / suspension Machinist / Suspension Machinist / Steering Machinist / Brakes
25
Deepak
Welding