IGIT YANTRIKI 2013

BAJA SAEINDIA

2013

Indira Gandhi Institute of Technology

Kashmere Gate, Delhi

DESIGN METHODOLOGY
Study Problem Statement

Subsystems

Terrain Requirement

Vehicle Features
Rulebook

Features to parameters to
values

Standards
Knowledge

TRADE OFF
Initial Design
Detailing
Optimization
using Software

FINAL
DESIGN

1/8/12

14/8/12

Virtual Baja
SAE

19/8/12

20/8/12

Fabrication
practices

1/7/12

31/8/12

Parts
procurement

1/9/12

30/9/12

Vehicle assembly

21/9/12

31/10/12

Vehicle testing

1/11/12

30/11/12

Marketing and
sponsorship

25/3/12

30/11/12

Final event

-/2/13

-/2/13

Feb

Design
compilation &
virtual
preparation

Jan

31/7/12

Dec

1/4/12

Nov

Design testing &

analysis

Oct

15/7/12

Sep

1/3/12

Aug

Paper napkin
Design and
calculations

Jul

31/7/12

Jun

14/2/12

May

Developing
Designing Skills

Apr

15/12/12

Mar

1/3/12

Feb

End

Star
t

Tas
k
Research &
Market Survey

SUSPENSION SYSTEM
DOUBLE WISHBONE NON PARALLEL, UNEQUAL ARMS

FACTORS
OPTIMISED
Swing arm lengths
Roll and pitch centre
heights
Side view instant centre
angle (Anti features)
Chassis mounting points
(Clearances)
Inclination of arms
Coil spring parameters
Damper mounting points

FRONT

REAR

Ground clearance - 11

Ground clearance - 11

Anti squat - 19 %

Anti squat - 14.8 %

Upper arm length 13.7

Upper arm length - 7.5

Lower arm length -15.5

Lower arm length -11.12

Front
Front ride rate:5.2726N/mm
Rear ride rate:7.5323N/mm
FRONT

REAR

Pre-load in spring
(mm)

21.02

32.027

Spring stiffness
(N/mm)

15.307377

19.282

Mean diameter( mm)

94

91

Natural length (mm)

304.8

279.4

Number of turns

Material used

Spring Steel, Grade 2

Type of shock absorber

Gas shock absorbers

Shock travel(mm)

152.4

104.013

Motion ratio

0.6

0.63

Rear

FINITE ELEMENT ANALYSIS

Front
knuckle

Rear
knuckle

Material - Aluminum
Series7

Material - Aluminum
Series7

Boundary condition DOF=0 at spindle

Boundary condition DOF=0 at spindle

FOS = 1.8386

FOS = 1.37

Lower A
arm (Front)

Upper A
arm (Rear)

Material AISI 1018

Material AISI 1018

Boundary condition DOF=0 at Chassis

Boundary condition DOF=0 at Chassis

FOS = 4.86

FOS = 1.49in

STEERING SYSTEM
RACK AND PINION
FACTORS
OPTIMISED
Exact Trapezoidal
Linkage

Lock to Lock Turns

Steering Ratio
Rack Travel
Zero Bumpsteer

GEAR BOX
Turning radius- 2.05 m
Lock to Lock turns- 1.2
Steering Ratio- 8.2:1
Rack Travel- 75.65mm
WHEEL ALIGNMENT
FRONT

REAR

Camber

-2

Caster

+4

Toe Angle

2 (out)

2 (in)

King Pin
Inclination

+8

+5

RACK:
Material: EN19
Total Length: 360mm
Cut Length: 145mm
No. of Teeth: 26
Pitch: 5.58mm

PINION:
Material: EN19
Diameter: 40mm
No. of Teeth: 22

FEA
Pinion
Material EN 19
Boundary condition DOF=0 at Pinion Shaft

Rack
Material EN 19

Boundary condition DOF=0 at Rack ends

FOS = 3.2

FOS = 4.4

INNOVATION
Multiple positions for tie rod end
on knuckle
Provides with varying steering
effort according to driver comfort
Varying Steering Feel to the
driver

5 second Egress mechanism for

driver
Steering wheel assembly swings
away from driver
Easy lever actuation at steering
wheel

WHEEL ASSEMBLY
TIRE AND RIM
Front
Rear

21x7x10
22x8x10

Wheel Offset = 0
BCD = 4
HUBS

Front Assembly
ROTOR
Front
Self Fabricated
Rear
Self Fabricated
Material
FG 300
CALIPER
Front
Pulsar 220 cc
Rear
Pulsar 220 cc
Fixed Caliper

Front
Self Fabricated
Rear
Self Fabricated
Material
AISI 1018
Rear Assembly

BRAKE ASSEMBLY
BRAKING SYSTEM
Disc Brakes
Front Rear Split
Dual Single MC set up- Yamaha R-15
Remote MC Reservoir

PEDAL ASSEMBLY
Pedal Ratio- 5.5:1 (Fixed)
Brake Pedal Angle= 60
Adjustable Brake Bias Bar

FINITE ELEMENT ANALYSIS

Front Hub
Material AISI 1018
Boundary condition DOF=0 at Hub Bolts
FOS = 1.51

Rear Hub
Material AISI 1018
Boundary condition DOF=0 at Hub Bolts
FOS = 1.4

ENGINE POWER TRAIN

REAR ENGINE- REARWHEEL DRIVE

ENGINE

10 HP Briggs and Stratton

Orientation- Forward
TRANSMISSION- Mahindra Alfa

Constant Mesh, 4 forward with 1 reverse.

HALF SHAFTS- Maruti 800 with refabricated Alfa shaft ends
FACTORS OPTIMISED

Clearance with Control Arms

Half Shafts operating angle
CALCULATED VALUES

Max speed : 51.6 km/hr

Grade ability : 51%
Maximum Grade : 27 deg

ENGINE POWER TRAIN

REAR ENGINE- REARWHEEL DRIVE
Hand clutch actuation combined
with gear shifter
Saves pedal swap time during
endurance race

Engine Transmission Sleeve and Flange

coupling
Allows coupling of B&S engine and
Mahindra Alfa

ROLL CAGE
SPECIFICATIONS
DESIGN METHODOLOGY
Structural Rigidity
Strength to weight ratio
Suspension Kinematics
Ergonomics
Placement & Positioning
Easy Access to Sub Systems
Aesthetics
Manufacturability
Cost Factor
BAJA SAEINDIA Rules

SAFETY
Kill Switch in
proximity
Easily
Detachable
Fire
Extinguisher
from mounting

Tube OD = 25.4mm
Tube Thickness = 3mm
Type of Welding = MIG

Panel Material
=Aluminium

ERGONOMICS
Boat Shaped Cage
Firewall inclination
Optimum Distance
between driver & steering
wheel=30cm
Clear field of vision

NVH proofing in
process

Front Impact
Force Applied 8750N
Maximum Stress = 325.7M Pa
Maximum Deformation = 0.0014m
FOS = 1.13

Rear Impact
Force Applied 8750N
Maximum Stress = 271.45M Pa
Maximum Deformation = 0.0018m
FOS = 1.4

Side Impact
Force Applied= 8750N
Maximum Stress = 187.2M Pa
Maximum Deformation = 0.0014m
FOS = 1.97

Roll Over Impact

Force Applied 3750N

Maximum Stress = 194.8 M Pa

Maximum Deformation = 0.0015m
FOS = 1.88

TECHNICAL SPECIFICATIONS

ENGINE

DIMENSIONS

INTERIOR

TYRES
BRAKES
SUSPENSION

STEERING
CHASSIS
ELECTRICALS
VEHICLE WEIGHT

Cylinder
Transmission
Dry Weight
RPM
Maximum torque
Maximum Power
Displacement
Type Of Engine
Overall Length
Overall Height
Overall Width
Fuel Tank Capacity

No.

Kg.
Nm

mm
mm
mm
L

Combimeter
Front
Rear
Type
Master Cylinder
Front
Rear
Shock Absorbers
Type
Steering wheel
Steering column
Sheet metal
Rollcage
Headlight bulb
Taillight bulb

mm
mm

in
mm

kg

Single
4-speed, Manual
30
3000-3800
23.7 @2600 rpm
8KW @ 4400 rpm
338 cc
4-stroke internal camshaft
2133.6
1524
863.6
6
Fuel Indicator
Tachometer
Speedometer
Reverse gear indication
177.8/33 R5
203.2/37 R5
Disc
Single, 0.5 Bore Diameter
Double wishbone
Double wishbone
Gas type
Rack and Pinion
13/D
25.4/R
Aluminum
AISI 1018
12V,2.91 amp,35W
12V,1.3amp, 16W
375(estimated)

BILL OF MATERIALS
DEARTMENT

SUB DEPARTMENT

NAME OF PART

FRONT

WHEEL ASSEMBLY

REAR

ROTOR ASSEMBLY

TYRE

RIM

HUB

HUB BEARING

LUG NUTS

KNUCKLE

SPINDLE

CASTLE NUTS

CARRIAGE BOLTS

TYRE

RIM

HUB

LUG NUTS

KNUCKLE

CASTLE NUTS

CARRIAGE BOLTS

ROTOR
CARRIAGE BOLTS

CALLIPER ASSEMBLY

BRAKES

PEDAL ASSEMBLY

QUANTITY

4
16

BRAKE PADS

CALLIPER

BANJO BOLT

BANJO-O-RING

CALLIPER MOUNTING BOLTS

BRAKE PEDAL

MOUNTING

SPHERICAL BEARING

BRAKE BIAS BAR

ROLLER BEARING

BARREL NUTS

MASTER CYLINDER

STEEL PIPELINES

DFMEA
Component

Function

Potential failure
mode(s)

Potential effect(s)

Potential cause(s)/mechanism(s) of
failure

SVV

OC
DTT RPN
C

Controls

Preventive
controls

Detective
controls

BRAKES

Rotor

Vibrational
Rotor absorbs the thermal
ressponse,Low and
energy created during
high frequency
braking action. It is the disc
squeal,Rotor cracks
of the disc brake.
and hot spot

Calliper

The brake calliper is the

Leakage of brake
assembly which houses the fluid,Caliper piston
brake pads and pistons.
slide get siezed

Brake pad(s)

Brake fluid

Brake lines

Cause the braking action for

deceleration of the vehicle

Wearing off

Travel of vibration to the

chassis,Inefficient braking

Hard brake pedal,brake pull

Inefficient braking, squeeling,

grabbing. Hard pedal which
eventually sinks to the floor.

Transmitting force applied

Hard brake pedal which
on the brake pedal onto the Change in properties
eventually sinks to the floor,
brake pads through fluid at high temperature
inefficient braking
pressure.

To carry brake fluid

Converts pressure from the

Master Cylinder brake pedal into hydraulic
power through brake fluid.

Rotor misaligned with brake pads,

calliper and wheel bearings while fitting
6
or due to wear & tear.
Poor Quality rotor without slots/holes.

Rotor with
adequate
weight & good
quality
7 294
Replacement
material &
spotted holes
for better heat
dissipation.

Friction b/w moving parts,sticky caliper

pins and pads

7 343

Good quality
brake pads
with higher
8 512 coefficent of Replacement
friction at high
temp's & good
quality oil seal

Wear & tear, Contaminated friction

material, Oil in brakes, Overheating

Good quality
material

Water & air contamination,Leakage in

brake lines

Periodic brake
fluid top-up.
Good quality
8 448
brake lines, &
DOT3 brake
fluid.

Pinching or cracking

Loss of brake fluid pressure &

leakage of fluid, Hard brake
pedal

Physical damage.

8 392

Pressure leak.

Inefficient braking

Foreign particles get in due to muddy

terrain, water gets in, improper sealing

8 336

Reinforced
steel brake
lines

Replacement

Total refill

Replacement

Proper sealing Replacement/R

of the cylinder
epair

DVP
PART
NAME

PART NO.

TIRE

TEST EQUIPMENT

TEST DESCRIPTION

ACCEPTANCE CRITERIA

Tire testing machine(intact 80)

A low pressure is generated in the

vacuum chamber , thereby
inducing deformations which are
caused by the expansion of air
pockets occurring in faulty areas
can be localized clearly and
reproducibly

Tire with 95% positive report is accepted

IMPACT LOAD TESTING MACHINE

Load is applied vertically by droping

a block

Accepted if it doesnt break

WA1

WHEEL

WA2

HUB

BRAKE1

Ansys software

Stress analysis by applying different

forces on the periphery of hub

Fos>1

BRAKE
FLUID

BRAKE2

Brake fluid testing machine

A sample(10ml) with a disposable

pipette transferring it to a
disposable specimen vial and
bringing I to boiling
point9immersion heater method)

Boiling point >350

BRAKE
PEDAL

BRAKE3

Brake pedal ratio testing machine

Three fixture plates used for pedal

set up.controller is programmed to
apply a set input load by keeping
the assembly static and balancing
he output load at the booster rod.

If pedal ratio=5.5:1

ROTOR

BRAKE4

Plate style tcs

Static hot plate testing:each tc held Force readings should not exceed 4 times
against hot plate(150&400C) for
the maximum error
120s.
Dynamic test:(3 cycles)each heating
cycle consists of snubs from
160kph to 5kph at 0.62g
deceleration level until a
temperature cut-off of 550C is
reached

Thank you!

Team IGIT Yantriki 2013