NAME-

CONTACT NO. –
EMAIL ID -

SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 1

VEHICLE SPECIFICATIONS
DIMENSIONS Steering 9.7:1
Overall 120” Ratio
Length Camber -2o
Overall 58” Caster 3o
Width KPI 7o
Overall 78” Turning 2.633m
Height Radius
Wheel Base 93” BRAKE
Front Track 50” Type Disc Brake
Width Diagonal
Rear Track 48” Split
Width Disc Maruti
Ground 14” 800
Clearance
Caliper Maruti
TYRES
Front 25x8x12 800
Rear 25x10x12 TMC Maruti 800
TRANSMISSION
ENGINE Type Manual
Company Maruti 800 Gearbox
and Model Company Polaris
Displacement 800cc RZR 570
Max. Output 45.9 hp Max. Speed 72 km/hr
Power Drive Type AWD
Max. Torque 34Nm ELECTRICAL
@7500 Battery Exide 12V
rpm 80 amp
Starting Electric
Lights Headlight
System Start
(x2),
Platform Three Flood
Cylinder, Light(x2),
Liquid 30” LED,
Cooled,4- Brake
Stroke Light
COOLING
STEERING Radiator Maruti 800
Company Maruti 800 Company
Type Rack and Size 14” x 14”
Pinion Weight 2.5kg
Ackermann
Material Al Fiber
Mechanism

SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 2


ABSTRACT:
The objective of this project is to design and
manufacture a racing vehicle for participation in
RCDC 2018.The vehicle is designed using
mathematical and computer-aided modeling and
simulation, resulting in a safe, high-performance
vehicle for off-road competition, with a light
weight, high strength, and high durability.
The aim of TEAM HORNET RACERS is to win
RCDC 2018 by making not only the best
performing vehicle but also the rugged and
economical vehicle that will comply the entire
RCDC 2018 design requirement.
components software like CATIA V5 R16,
ANSYS15, KEY SHOT is used. Based on
analysis results, the model was modified and
retested and a final design was frozen.
REQUIREMENTS OF A VEHICLE:
1. Low cost but durable
2. Endurance
3. Parts easily available for maintenance
4. Optimum Speed and Acceleration
5. Safety
6. High efficiency
7. Ergonomically sound design
With this we had a view of our ATV. This started
our mission and we set up some parameters for
our work, distributed ourselves in groups.

INTRODUCTION: SUB-TEAMS FOR DESIGN

RCDC 2018 event is organized by POLARIS. The Chassis
teams are given the challenging task to design and Steering
fabricate a double seater off-road, rugged, Braking
recreational and fun to drive vehicle which will Transmission
intended for sale to weekend on road enthusiasts. Suspension
Electrical System
The goal of TEAM HORNET RACERS is to Our main aim was to work under the guidelines of
make the best performing car that will comply all the rule book, and use the maximum limits.
RCDC 2018 design requirement. To achieve our
goal team has been divide into various groups and CHASSIS:
each group is assigned a specific component of
the vehicle (Chassis, Steering, Suspension,
Brakes, Power Transmission, and Wheel
Assembly).

The team is focused to, design the vehicle by

keeping in mind the RCDC 2018 requirements,
driver’s and navigator comfort and safety, to
increase the performance and drive ability of the
ATV.

We approached our design by considering all

possible alternatives for a system & modeling &
MAIN CHASSIS
analysis them in CAD & CAM software. For
designing, analysis and optimization of the vehicle Parameters Considered while designing Chassis: -
SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 3
 Driver Ergonomics Engine & Transmission Specifications:-
Engine (Polaris RZR 570)
Displacement 567cc
Drive Layout
Platform Single Cylinder, Liquid
Suspension Cooled, 4stroke, DOHC
Gross Vehicle Weight Horsepower (hp) 45.9 hp
Wheel Assembly Max Torque 34Nm @ 7000 rpm
Bore & Stroke 99 x 73.6 mm
Compression Ratio 10:1
Max RPM 7750
Optimum Speed 30 kmph
Transmission Type Polaris Automatic PVT
Tire Size Front – 25 x 8 x 12
Rear – 25 x 10 x 12
FNR Ratio Forward – 10.1:1
Final – 2.5:1
Differential Front – 2.5:1
Rear – 2.5:1
PVT Drive Ratio Front – 3.818:1
Final – 3.70:1
DRIVER ERGONOMICS Shift Type Inline – H/L/N/R/P
Normal Operating RPM 7500
Material Grade AISI 1018 Drive Type All Wheel Drive
Composition C=0.18%, Mn = 0 .663 Muffler Endurance
%, P= 0.018%, S=0 .0168 Exhaust Pipe Length – 12”
Yield stress 370 N/mm² Diameter – 1.5”
Ultimate stress 440 N/mm² Back Pressure – 2.58 kPa
Density 7800 kgm-3 Axel Length – 17”
Poisson’s ratio 0.29 Diameter – 1.5”
Radiator Size 14” x 14”
Tube specifications OD= 1.26” (32 mm)
Heat Supplied by Fuel 5341.5 KJ/min
Thickness = 0.137” (3.5 Heat Equivalent to 1602.21 KJ/min
mm) Brake Power
ENGINE & TRANSMISSION: Heat taken away by 835.84 KJ/min
cooling water from
Objective: Engine is heart of automobile. Engine cylinder
Heat taken by Exhaust 2903.45
generate power through combustion of fuel. This
gases and Unaccounted
generated power is transmitted to tires through losses
transmission system. To meet Terrain conditions
we have selected POLARIS RZR 570 engine and
POLARIS AUTOMATIC TRANSMISSION Power (hp) RPM Torque(Nm) Speed(kmph)
(PVT) and AMK INDUSTRY manufactured FNR 35.2 hp for 5000 50.153 48.11
Straight 6000 41.794 57.74
and DIFFERENTIAL will be used. After all Path 7500 33.435 72.18
radiator calculation we have decided to choose 37 hp for 5000 51.566 48.11
MARUTI 800 radiator and ENDURANCE 30o inclined 6000 42.972 57.74
Muffler. Selected Air Filter is of UNIVERSAL path 7500 34.377 72.18
Cylindrical shape air filter.

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 diameter(in.)
Master Cylinder used TATA NANO
Pedal ratio 6:1
Weight of the car with 570
Driver (kg)
Dynamic Weight Front – 47%
Distribution Rear – 53%
Stopping Distance Without slip – 5.14m
With slip – 5.05m
Stopping Time Without slip – 2.735s
With slip – 2.715s
ALL WHEEL DRIVE LAYOUT Optimum Speed 30 kmph

DAIGONAL SPLIT

STEERING SYSTEM:
Objective: The steering system is the key
COOLING SYSTEM LAYOUT interface between the driver and the vehicle.
Steering is a set of mechanisms used to control the
BRAKE SYSTEM:
trajectory of the vehicle. The basic aim of steering
Objective: The purpose of the braking system is is to ensure that the wheels are pointing in desired
to increase the safety and maneuverability of the directions and to allow the driver to guide the
vehicle by statically and dynamically locking all vehicle. After calculation we have selected
four tires on both paved and unpaved surfaces. MARUTI 800 Steering assembly since it meets all
our steering requirement.
Name of the Description
component

Brake Type Disc Brakes

Split Type Diagonal Split type
Disc diameter (in.) 7.87
Disc Used Maruti 800
Caliper piston 1.14
diameter (in.) RACK & PINION
Caliper Used Maruti 800
Caliper Type Single Piston Caliper
Master cylinder bore 0.77
SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 5
 FRONT SUSPENSION GEOMETRY
TURNING RADIUS

Steering ratio 9.7:1

Rack travel 34.15 per 360o pinion
revolution
Front track width 50 inch
Wheel base 68 inch
Inner lock angle 35o
Outer lock angle 24.808o REAR SUSPENSION GEOMETRY
Caster 3o
SAI 7o
Camber -2o
Scrub radius 101.38mm
Toe in & Toe out 0o
Turning radius 2.633m
SUSPENSION SYSTEM:
Objectives: The suspension is one of the most
crucial part of vehicle. It’s main purpose is to
prevent the road shocks from being transmitted to
the vehicle parts, thereby providing suitable riding
CONTROL ARM
and cushioning effect to the occupants. It helps to
keep vehicle stable while in motion by providing Sprung Weight 475 kg
good road holding during driving, cornering and KPI 7o
braking. It provides safe vehicle control and free Knuckle Length 228.6 mm
Knuckle Material EN 24
of irritating vibrations. It also helps to maintain Front Control Arm Upper – 348.71mm
the surface contact of wheels with the road better Lower – 396.84mm
stability, ride and comfort for the driver. Selected Rear Control Arm Upper – 330.32mm
wishbone material is AISI 4130 as it is to have Lower – 378.68mm
Control Arm Material AISI 4130
better material strength and lower weight along Spring Material ASTM A228
with the optimum cost of material. Similarly Front Spring Stiffness – 78 N/mm
selected material for knuckle is EN24. Selected Coil Dia. – 15mm
Spring material is ASTM 228 since it is toughest Mean Dia. – 90mm
Active Coils – 9
and most widely used and front damper of Solid Length – 165mm
PIAGGIO APE is used. Pitch – 29.644mm
Free Length –296.445mm

SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 6

Rear Spring Stiffness – 106.62 N/mm
Coil Dia. – 18mm
Mean Dia. – 108mm
Active Coils – 8
Solid Length – 180mm
Pitch – 35.55mm
Free Length –320mm
Max Wheel Travel 9”
Max Spring Travel 5”
FOS 2
LIGHTS LAYOUT

ELECTRICAL SYSTEM:
Objective: The Electrical system is like Nervous ANALYSIS:
system in human body It controls the all vehicle Front Impact-
parts. It is the key interface between the Car and
Driver. It is the set of ECU , Lights, Motors , Force 4G ( 22366.8N)
Battery etc used in cars. The main roll of Element Size 5mm
Max Shear Stress 2136.343 MPa
electrical system is the controls a series of
Max Deflection 187mm
actuators on an internal combustion engine to Factor of Safety 2.52
ensure optimal engine performance and controls
all electric parts .

Electrical Components Required:

ECU
Battery ( 12V, 80amp)
SHEAR STRESS DEFORMATION
Headlight
Brake light Side Impact-
30” LED
Fuel Gauge Force 2G ( 11183.4N)
Speedometer Element Size 5mm
Max Shear Stress 447 MPa
Kill Switch Max Deflection 23.7mm
Radiator Cooling Fan Factor of Safety 2

DEFORMATION SHEAR STRESS

Roll Over-
COOLING FAN LAYOUT
Force 1G ( 5591.7N)
Element Size 5mm
SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 7
Max Shear Stress 397 MPa
Max Deflection 23.3mm
Factor of Safety 2.3

BRAKING MAX. FORCE ON LOWER WISHBONE

BRAKING
Factory of Safety = 3 WISHBONE
DEFORMATION SHEAR STRESS
Knuckle-
Torsional-
Maximum force acting on knuckle is 6000N.
Force 1G ( 5591.7N) Maximum force acting on steering arm while
Element Size 5mm turning is equal to force along tie rod i.e 422N this
Max Shear Stress 372 MPa force is applied at steering arm .
Max Deflection 51.3mm
Factor of Safety 2.5 Maximum Stress Developed = 42.42 Mpa
Maximum Deformation = 0.00581 mm
Factor of safety = 2.96

DEFORMATION SHEAR STRESS

Wishbone-
Parameters 1m Brakin Max. Max.
Fall g Force Force
on on
Lower Upper
Wishbo Wishbo
ne ne
Force (N) 25196 5719 9641.32 6094.94
Stress 524 424 77.8 89.5
(N/mm2)
Deformatio 0.88 0.9931 0.07975 0.121 ANALYSIS OF KNUCKLE
n
(mm) Hub-
We have done calculation on braking system to
find out the required braking torque and the
braking which will apply on the hub. From
calculation we get the braking torque about
303.163Nm. and braking force about 6300N. We
BRAKING MAX. FORCE ON UPPER WISHBONE
used the ANSYS software to find out the whether
BRAKING
WISHBONE
SKILLDX- BASIC OF RACE CAR DESIGN INTERNSHIP Page 8
the hub failed or sustain. The result from the
ANSYS shows that the design is safe.

Factor of Safety = 2.65

HUB ANALYSIS

ASSEMBLED VEHICLE

CONCLUSION:
TEAM HORNET RACERS objective and motive
at RCDC 2018 is to design and build a two seater
ATV that can complete all events in “RCDC
2018’’without failure and to excel in the game.
All designs and calculations were done to realize
this aim.

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