PROJECT REPORT

HYPERLOOP POD DESIGN

GROUP MEMBERS
 ANAS IMDAD
 ISRAR AHMED
 ABDULLAH TOFIQUE
 M.ERSALAN ANWAR

SUBMITTED TO: AP JAMAL SAEED

SUBMISSION DATE : JANUARY 13, 2017

1
 Introduction
This project is all about designing the Hyperloop pod with the given and adequate
conditions. Hyperloop is a future technological vehicle that will be able to transport people
from one place to another at a speed of 1000km/h particularly due to the low pressure and
thus resulting in less friction acting on it. The idea of Hyperloop was proposed by the
Founder of SpaceX Elon Musk who is quite confident in building this mode of transport. The
basic purpose of this is to transport the people efficiently and thus shortening the distances
between towns or cities due to its superlative speed. Due to its vast idea and concept, Elon
Musk also conducted the competition among different universities of the World and escalated
the best concepts out of it. It will transport 28 people and will include batteries, chassis,
propulsion system etc. The main challenge is to build it safe and sound and we hope that he
will be able to do that.

Methods
The method we employed was started from the length of hyperloop. Initially, we
proposed a length of 13m but that was not fulfilling our requirements especially of the chair
length and the spacing between the chairs. So we decided to build the adequate chair first of
suitable length and construct the further design according to it. So the chair was the starting
point in the designing of our Hyperloop. The weight of the person we took was 90kg (883N).
From different sources on Internet, we found that 13% of the weight act on back seat and
78% of the weight act on the sitting area. First of all, the chair was sectioned from the edge
(as if we are looking from side view). We calculated all the forces and after finding all the
forces, we took the base support of chair (where the person sits). The main purpose of it was
to find the forces of the pillars of the chair on cross members of chassis. We designed a two
pillar chair as it is the most stable one which has been proved in calculations as well. Then
after designing chair, the suitable length of Hyperloop that came out to be was 15m.

After this, we went on shell. First we made a chassis of random thickness that was quite large
but after certain calculations, we reduced it. Then we moved towards shell. The biggest
problem is designing the shell was to decide what will be its thickness? So we made a
random thickness shell just like chassis but after some certain considerations and analysis, we
came to know that our shell was of very high thickness. So we reduced the thickness to
0.00058m.

Then we moved towards the door. Door position was a major concern as Hyperloop
contained battery at the back and propulsion system in the beginning. So after careful
considerations, we decided to make it forward and of suitable size as well. We made the
bending and shear moment diagrams wherever we felt. All the calculations have been shown
in this report.

2
The positioning and number of tires was a major problem for us. We decided to use two tires
after long calculations of shear force and bending moment diagrams which have been shown
in the report. The positioning of tire is decided after careful considerations of deflection and
bending. After this, it is also checked whether chassis will be able to bear all load or not. The
major concern was choosing the suitable material for different parts. Most of the parts were
made up of Aluminum and only one type of part was made of steel which is supporting the
plates. It was quite important because both mass and yield strength are totally dependent on
the type of material we chose.

Drawings, Parts List and Bill of Materials

 Drawings:

a) Rendering

3
4
b) Isometric Views

Chair

5
Chassis

6
 Shaft

Entrance Door

7
Shell

8
  Bill of Materials

Item No Description Quantity Specifications Cost Total cost

1 Aluminum 28 (In Report) 50 $ 1400 $
Chair
2 Stainless 112 (8mm x 0.1 $ 11.2 $
Steel A-2 Nut 1.25mm)
3 Stainless steel 112 M5 x 0.8 mm 4$ 448 $
A-2 Bolt
4 ASTM A240 1 (Thickness 5000 $ 5000 $
Steel Sheet 0.01m,Area
0.02m^2)
5 Chassis 1 Area 0.08m^2 10000 $ 10000 $
Thickness
0.05m
6 Aluminum 1 200 $
Shell
7 Aluminum 1 100 $ 100 $
Door
8 Engine 4 Ratio of 20:1 250 $ 1000 $
components
9 Batteries, 10 12v 150 $ 1500 $
motor

9
 Seating Arrangement:

10
 Assumptions

 All loads are considered to be point loads for the sake of convenience except shell whose
load is taken as distributed.

 Acceleration considered is 0.5g.

1. Chair Assumptions
 A human body of 90 kg is considered (882.9 N).
 The inclination angle is 115o
 Chair is made up of Aluminum material.

 Back Rest
 The weight of the human body at the back is 13% of the actual weight.[1]
1
 The weight of the human body is concentrated at a 4th distance from the top
of the back rest.

 Sitting Area
 The weight of the human body at the sitting area is 78% of actual weight.
1
 It is concentrated at a 3rd distance from the back rest.

 Pillars
 Pillars are fixed at both ends.

 Bottom Aluminum and Steel Plate

 All bolts sustain equal amounts of compressive and shear loads.
 All bolts produce same reaction moments.

2. Shell and Door Assumptions

 The shell is also made up of Aluminum material.
 Uniform distribution of hoop stress.
 Pressure of supporting frame is negligible on the shell.
 Factor of Safety is taken as 2.

11
3. Chassis Assumptions
 Cross members are made of steel.
 The side/edge of the chassis is made of Aluminum.
 The plate above the cross members is made of steel.
 The Battery is placed on the steel plate.
 The mass of the battery is considered to be 272 kg.
 The weight of the battery is also concentrated at a single point.
 The Propulsion system is placed on the steel plate.
 The weight of the propulsion system is taken to be 4905 N.
 The Propulsion system is placed on the steel plate.
 The propulsion system is placed at the right lower end of the hyperloop and its weight
is concentrated.
 The propulsion system is placed in an area of 0.62x0.79 m2
 The weight of the shell is distributed.

12
Data Section

 Materials Data Table

[2]

Calculations

 Chair Analysis

Back Rest
Side view (yz-plane):

13
 Rotating the beam for our convenience, we get

𝐴𝑟𝑒𝑎 = 0.36 𝑚2

𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑒𝑟𝑠𝑜𝑛 = 882.9 𝑁
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑒𝑟𝑠𝑜𝑛 𝑜𝑛 𝑡𝑕𝑒 𝑏𝑎𝑐𝑘 𝑟𝑒𝑠𝑡 = 0.13 × 882.9 = 114.77 𝑁
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝐵𝑎𝑐𝑘 𝑅𝑒𝑠𝑡 = 0.36 × 0.015 × 2800 × 9.81 = 148.32 𝑁

𝐴𝑧 = 114.77 cos 25° = 104.02 𝑁

𝐴𝑦 = 148.32 + 114.77 sin 25° = 196.82 𝑁
𝑀𝐴 = 148.32 × 0.33 + (114.77𝑠𝑖𝑛25° × 0.495) = 72.96 Nm

14
 Shear Force & Bending Moment Diagrams

Now let’s have a look at the Back-Rest cross-section and find the maximum stress there

15
 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑀𝑜𝑚𝑒𝑛𝑡 = 72.96 𝑁𝑚

1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.55 × 0.0153 = 1.55 × 10−7 𝑚4
12 12
𝑀𝑐 72.96 × 0.0075
𝜎𝑚𝑎𝑥 = =
𝐼 1.55 × 10−7

𝜎𝑚𝑎𝑥 = 3.53 𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑

Sitting Area
Side view (yz-plane):

𝐴𝑟𝑒𝑎 = 0.36 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑆𝑖𝑡𝑡𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 = 0.36 × 0.015 × 2800 × 9.81 = 148.32 𝑁

2𝐶𝑦 = 148.32 + 688.662 + 196.82 = 1033.802 𝑁

𝐶𝑦 = 516.901 𝑁

2𝐶𝑧 = 104.02 𝑁
𝐶𝑧 = 52.01 𝑁

2𝑀𝑐,𝑥 = 688.662 × 0.295 − 0.227 + 196.82 × 0.295 + 72.96 − 148.32 × 0.34 − 0.295
2𝑀𝑐,𝑥 = 171.18 𝑁𝑚
𝑀𝑐,𝑥 = 85.59 𝑁𝑚

16
Shear Force & Bending Moment Diagrams

17
Front View (x-y plane):

𝐴𝑟𝑒𝑎 = 0.36 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑖𝑡𝑡𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 = 0.36 × 0.015 × 2800 = 148.32 𝑘𝑔
𝐶𝑦 𝑙 516.901 × 0.36
𝑀𝑐,𝑧 = = = 23.26 𝑁𝑚
8 8

18
 Shear Force & Bending Moment Diagrams

If we look at the Moment diagram, we get a maximum clockwise bending moment of 69.78 Nm

We get a maximum bending moment on the x and z axis. Let’s find out the maximum
compression and tension in x-z plane.

19
Looking at the figure, maximum tension will occur at point A and maximum compression at
point B.

1 1
𝐼𝑥 = 𝑏𝑕3 = 0.55 × 0.683 = 0.0144 𝑚4
12 12
1 1
𝐼𝑧 = 𝑏𝑕3 = 0.68 × 0.553 = 9.43 × 10−3 𝑚4
12 12

177.85 0.295 69.78 0.275

𝜎𝐴 = + = 5.68 𝑘𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
177.85 0.385 69.78 0.275
𝜎𝐵 = − − = −6.79 𝑘𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧

The Shear stress acting on the seat surface can be determined as

104.02
𝜏= = 288.94 𝑃𝑎 < 𝜏𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
0.36

20
 Pillars

Side View of Pillar (y-z plane):

𝐴𝑟𝑒𝑎 = 0.1 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.01 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑖𝑙𝑙𝑎𝑟 = 0.1 × 0.01 × 2800 × 9.81 = 27.47 𝑁

𝐷𝑦 = 516.901 + 27.47 = 544.371 𝑁

𝐷𝑧 = 52.01 𝑁

𝑀𝐷,𝑥 = 52.01 × 0.34 + 85.59 = 103.273 𝑁𝑚

21
Top of the Pillar (x-z plane):

Two moments are acting at the top of pillar because of the Sitting Area. One moment is in x-
direction while the other in z direction.

The Moment of inertias can be found as

1 1
𝐼𝑥 = 𝑏𝑕3 = 0.01 × 0.273 = 1.64 × 10−5 𝑚4
12 12
1 1
𝐼𝑧 = 𝑏𝑕3 = 0.27 × 0.013 = 2.25 × 10−8 𝑚4
12 12

Maximum Tension will be at point A and Maximum Compression at Point B

85.59 −0.135 23.26 0.005

𝜎𝐴 = − + = 5.87𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
85.59 0.135 23.26 −0.005
𝜎𝐵 = − + = −5.87𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
52.01
𝜏= = 5201 𝑃𝑎 < 𝜏𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
0.01
Buckling of the Pillar:
We need to find out whether the pillar we are using will buckle or not. Let’s take the weaker axis
which is “x”.

1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.01 × 0.273 = 2.25 × 10−8 𝑚4
12 12
𝜋 2 𝐸𝐼
𝑃𝑐𝑟 =
𝐾𝐿 2
𝜋 2 𝐸 × 2.25 × 10−8
𝑃𝑐𝑟 = = 530.19 𝑘𝑁 > 516.901 𝑁 (𝑠𝑜 𝑖𝑡 𝑤𝑜𝑛′ 𝑡 𝐵𝑢𝑐𝑘𝑙𝑒)
(0.5 × 0.34)2

22
 Bottom Plate + Steel Sheet

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0. 02 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.0015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.02 × 0.0015 × 2800 × 9.81 = 0.824 𝑁

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑆𝑕𝑒𝑒𝑡 = 0. 02 𝑚2

𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑆𝑕𝑒𝑒𝑡 = 0.01 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 8050 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.02 × 0.01 × 8050 × 9.81 = 15.79 𝑁

2𝐹𝑦 = 544.371 + 0.824 + 15.79 = 560.985 𝑁

𝐹𝑦 = 280.49 𝑁

2𝐹𝑧 = 52.01 𝑁
𝐹𝑧 = 26 𝑁

Taking Moment about one Bolt

0.55
2𝑀𝑁,𝑥 = 103.273 − 280.49 × 0.55 + 560.985 ×
2
𝑀𝑁,𝑥 = 51.64 𝑁𝑚

23
 Shear Force & Bending Moment Diagrams

If we look at the bending moment diagram, the maximum moment that exists is at the x-axis
which is 128.93 Nm.
The steel part is of 1cm and Aluminum of 0.15cm. So, net height is 1.15cm

24
 1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.03 × 0.01153 = 3.80 × 10−9 𝑚4
12 12
0.0115
128.93 × 2
𝜎𝑚𝑎𝑥 =
3.8 × 10−9 𝑚4

𝜎𝑚𝑎𝑥 = 195 𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑 𝑎𝑛𝑑 𝜎𝑠𝑡𝑒𝑒𝑙 ,𝑦𝑖𝑒𝑙𝑑

Both compressive stress and tensile stress will have the same values. The above material is
aluminum and the one below is steel. So, we have to make sure it doesn’t exceed any of them.

Now let’s check vertical deflection of the Steel plate.

𝑏𝑟𝑒𝑎𝑑𝑡𝑕 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 𝑏 = 0.03 𝑚
𝑕𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 𝑕 = 0.01 𝑚
𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.55 𝑚
𝐸𝑙𝑎𝑠𝑡𝑖𝑐 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 𝐸 = 200 × 109 𝑃𝑎
1 1
𝐼= 𝑏𝑕3 = 0.03 × 0.013 = 2.5 × 10−9 𝑚4
12 12

𝐹𝐿3 560.985 × 0.553

𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = = = 3.89 𝑚𝑚
48𝐸𝐼 48(200 × 109 × 2.5 × 10−9 )

 Shell and Door Analysis

We need to design a support to support the shell from collapsing, let’s say we allow a deflection
of 4mm only.
So the needed weight of the support can be found using the formula
48𝐸𝐼𝛥
𝐹= = 1034.4 𝑁
𝐿3

We need a support of 1034.4 N to support the shell.

The Area of contact can be found as
1034.4
𝐴𝑟𝑒𝑎 = = 64.93𝑚2
9.81 × 2800 × 0.00058

25
 Shell Thickness

𝜎𝑦𝑖𝑒𝑙𝑑 ,𝑎𝑙 = 240 𝑀𝑃𝑎

𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = 120 𝑀𝑃𝑎

𝑡 = 𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 𝑃𝑟/𝑡

Internal Pressure is taken as atmospheric Pressure and external is given to be 100 Pa.
Radius of shell is 0.7m

(101325 − 100)(0.7)
𝑡= = 0.59 𝑚𝑚
120 × 106

This will be the thickness of our shell.

The total area of shell is calculated using Solid Works and comes out to be:
𝐴 = 66.13 𝑚2
𝑡 = 0.00059 𝑚
𝑘𝑔
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 2800 3
𝑚
𝑊𝑒𝑖𝑔𝑕𝑡 = 2800 × 66.13 × 0.00059 × 9.81 = 1071.71 𝑁

26
 Door

Door Area using Solid Works

𝐴 = 1.01 + 0.82 + 0.15 = 0.124 𝑚2
𝑡 = 0.00059 𝑚
𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐷𝑜𝑜𝑟 = 2.73 × 10−4
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝐷𝑜𝑜𝑟 = 0.124 × 0.00059 × 2800 × 9.81 = 2.01 𝑁
𝐹𝑜𝑟𝑐𝑒 𝑏𝑦 𝑠𝑕𝑒𝑙𝑙 𝑜𝑛 𝑑𝑜𝑜𝑟 = 120 × 106 × 2.73 × 10−4 = 32760 𝑁

Reaction Force by railing on Door

32760 − 2.01 = 32.76 × 103 𝑁
Moment at the point where the door meets the shell
𝑀 = 32.76 × 103 1.6 − 0.7 = 29.484 × 103 𝑁𝑚

Applying Flexure Formula for curved Beam

𝑟2 0.7
𝑅 = 𝑏𝑙𝑛 = 0.91𝑙𝑛 = 0.075403 𝑚𝑚
𝑟1 0.699942

𝑟 = 0.69971 𝑚

29.484 × 103 (0.000075403 − 0.7)

𝜎𝑚𝑎𝑥 ,𝑐𝑜𝑚𝑝 = = −154.35 𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
2.73 × 10−4 × 0.7 × (0.69971 − 0.000075403)

27
 Shell with Chassis

The shell and the supporting frame are welded on the chassis. We need to find the centroid first;

0.45 × 1.89 + 0.49 × 1.25 + 2 × 0.384 × 3.83

𝑦= = 0.4475 𝑚
1.83 + 0.49 + 0.384 × 2

2𝐹𝑤 ,𝑦 = 2106.11 𝑁
𝐹𝑤 ,𝑦 = 1053.055 𝑁

𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛 = 0.02 𝑚2

1053.055
𝜎= = 52.653 𝑘𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
0.02

28
  Chassis

Cross Member Thickness

The place where the seats are connected with the chassis, we need to find out whether they are
stable or not.
The weight of the steel plate and the reaction forces are acting as shown in the figure.
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑆𝑡𝑒𝑒𝑙 𝑝𝑙𝑎𝑡𝑒 = 15.79𝑁
𝑅𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝐹𝑜𝑟𝑐𝑒𝑠 280.49𝑁

280.49 × 0.22 + 280.49 × 0.62 + 15.79 × 0.42

𝐹𝑦 = = 288.39 𝑁
0.84

29
 Shear Force & Bending Moment Diagrams

According to the bending moment diagram, the maximum moment is found to be 65.02Nm
We need to find its necessary thickness that will sustain this amount of weight.
𝑀𝑐
𝜎=
𝐼
𝑊𝑖𝑑𝑡𝑕 = 0.1 𝑚
Using a factor of safety of 2, we get the allowable stress 125 MPa for steel.
65.02 × 𝑡/2
125 × 106 =
1 3
12 × 0.1 × 𝑡

𝑡 = 5.59 𝑚𝑚

We have used a cross member with 8mm width. So, it won’t deform.

30
 Propulsion System

The Propulsion system is placed in an area of 0.62x0.79 and is placed on the 1cm steel plate. We
need to find out whether the Steel plate will sustain the weight or not.

𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑟𝑜𝑝𝑢𝑙𝑠𝑖𝑜𝑛 𝑆𝑦𝑠𝑡𝑒𝑚 = 4905 𝑁

𝐿𝑒𝑛𝑔𝑡𝑕 = 0.793 𝑁
𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 200𝐺𝑃𝑎
1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = × 0.62 × 0.013 = 5.16 × 10−8 𝑚4
12

𝐹𝐿3 4905 × 0.793

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = = = 4.88 𝑚𝑚
48𝐸𝐼 48 × 200 × 109 × 5.16 × 10−8 𝑚4

Battery System
As battery is lighter than the propulsion system and is placed on the same steel plate as it. So, we
will assume that the steel plate will also not deform because of the weight of the Battery. The
battery is actually placed at a very complex position so it’s difficult to find the concentrated line
of action of the force.

31
 Chassis One Side

The moment that is acting on the chassis by the seats is found using the free body diagram
below. One seat is exerting 51.64Nm on one end of the chassis in clockwise direction. The
weight of the chassis is found as shown below. While the shell weight exerting on the chassis is
found by the shell weight concentration we have found above. The length of the chassis is
14.99m.

𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑕𝑎𝑠𝑠𝑖𝑠 = 0.08 × 0.05 − 0.03 × 0.05 = 2.5 × 10−3 𝑚2

𝑉𝑜𝑙𝑢𝑚𝑒 = 14.99 × 2.5 × 10−3 = 0.037475𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 = 2800 × 0.037475 × 9.81 = 1029.36 𝑁
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑠𝑕𝑒𝑙𝑙 = 64.70 × 14.99 = 969.85 𝑁
𝑊𝑛𝑒𝑡 = 1999.216 𝑁

Taking Moment at A
𝐹𝐵 = (722.96 + 1999.216 ∗ 4.345 )/11.5
𝐹𝐴 = 818.22 𝑁
𝐹𝐴 = 1999.216 − 818.22 = 1180.996 𝑁

32
 Shear Force & Bending Moment Diagrams

From the bending moment diagram, the maximum moment is found to be 4037.11 N.

33
Now, Maximum Bending Stress is found to be

𝑀𝑐 4037.11 × 0.025
𝜎= = = 140 𝑀𝑃𝑎 < 𝜎𝑦
𝐼 1 3 1 3
12 0.08 0.05 − 12 (0.05)(0.03 )

Thus, our Chassis is also stable.

Considering Acceleration

 Chair Analysis

Back Rest Analysis

Side view (y-z plane):

Rotating the beam for our convenience, we get

34
 𝐴𝑟𝑒𝑎 = 0.36 𝑚2

𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑒𝑟𝑠𝑜𝑛 = 882.9 𝑁

Now the person sitting also applies an extra force of

𝐹 = 𝑚𝑎 = 90 × 0.5 × 9.81 = 441.45 𝑁
𝑁𝑒𝑡 𝑓𝑜𝑟𝑐𝑒 𝑏𝑦 𝑕𝑢𝑚𝑎𝑛 𝑏𝑜𝑑𝑦 = 441.45 + 882.9 = 1324.35 𝑁

𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑝𝑒𝑟𝑠𝑜𝑛 𝑜𝑛 𝑡𝑕𝑒 𝑏𝑎𝑐𝑘 𝑟𝑒𝑠𝑡 = 0.13 × 1324.35 = 172.166 𝑁

𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝐵𝑎𝑐𝑘 𝑅𝑒𝑠𝑡 = 0.36 × 0.015 × 2800 × 9.81 = 148.32 𝑁

𝐴𝑧 = 172.166 cos 25° = 156.035 𝑁

𝐴𝑦 = 148.32 + 172.166 sin 25° = 221.08 𝑁
𝑀𝐴 = 148.32 × 0.33 + (172.166𝑠𝑖𝑛25° × 0.495) = 84.96 Nm

Shear Force & Bending Moment Diagrams

35
Now let’s have a look at the Back-Rest cross-section and find the maximum stress there

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑀𝑜𝑚𝑒𝑛𝑡 = 84.96 𝑁𝑚

1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.55 × 0.0153 = 1.55 × 10−7 𝑚4
12 12
𝑀𝑐 84.96 × 0.0075
𝜎𝑚𝑎𝑥 = =
𝐼 1.55 × 10−7

𝜎𝑚𝑎𝑥 = 4.111 𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑

Sitting Area
Side View (y-z plane):

𝐴𝑟𝑒𝑎 = 0.36 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑆𝑖𝑡𝑡𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 = 0.36 × 0.015 × 2800 × 9.81 = 148.32 𝑁

2𝐶𝑦 = 148.32 + 688.662 + 221.08 = 1058.062 𝑁

𝐶𝑦 = 529.30 𝑁

36
 2𝐶𝑧 = 156.035 𝑁
𝐶𝑧 = 78.0175 𝑁

2𝑀𝑐,𝑥 = 688.662 × 0.295 − 0.227 + 221.08 × 0.295 + 84.96 − 148.32 × 0.34 − 0.295
2𝑀𝑐,𝑥 = 190.33 𝑁𝑚
𝑀𝑐,𝑥 = 95.165 𝑁𝑚

Shear Force & Bending Moment Diagrams

37
Front View (x-y plane):

𝐴𝑟𝑒𝑎 = 0.36 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑖𝑡𝑡𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 = 0.36 × 0.015 × 2800 = 148.32 𝑘𝑔
𝐶𝑦 𝑙 529.30 × 0.36
𝑀𝑐,𝑧 = = = 23.81 𝑁𝑚
8 8

Shear Force & Bending Moment Diagrams

38
If we look at the moment diagram, we get a maximum clockwise bending moment of 71.46 Nm

We get a maximum bending moment on the x and z axis. Let’s find out the maximum
compression and tension in x-z plane.
If we look at the figure, maximum tension will occur at point A and maximum compression at
point B.

1 1
𝐼𝑥 = 𝑏𝑕3 = 0.55 × 0.683 = 0.0144 𝑚4
12 12
1 1
𝐼𝑧 = 𝑏𝑕3 = 0.68 × 0.553 = 9.43 × 10−3 𝑚4
12 12

197 0.295 71.46 0.275

𝜎𝐴 = + = 6.12 𝑘𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
197 0.385 71.46 0.275
𝜎𝐵 = − − = −7.35 𝑘𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧

The Shear stress acting on the seat surface can be determined as

156.035
𝜏= = 433.43 𝑃𝑎 < 𝜏𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
0.36

39
 Pillar
Side View of Pillar (y-z plane):

𝐴𝑟𝑒𝑎 = 0.1 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.01 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑖𝑙𝑙𝑎𝑟 = 0.1 × 0.01 × 2800 × 9.81 = 27.47 𝑁
𝐷𝑦 = 529.30 + 27.468 = 556.498 𝑁
𝐷𝑧 = 78.0175 𝑁

𝑀𝐷,𝑥 = 78.05 × 0.34 + 95.165 = 121.702 𝑁𝑚

Top of the Pillar (x-z plane):

Two moments are acting at the top of pillar because of the Sitting Area. One moment is in x-
direction while the other in z direction.

40
The Moment of inertias can be found as
1 1
𝐼𝑥 = 𝑏𝑕3 = 0.01 × 0.273 = 1.64 × 10−5 𝑚4
12 12
1 1
𝐼𝑧 = 𝑏𝑕3 = 0.27 × 0.013 = 2.25 × 10−8 𝑚4
12 12

Maximum Tension will be at point A and Maximum Compression at Point B

95.165 −0.135 23.81 0.005

𝜎𝐴 = − + = 6.07𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
95.165 0.135 23.81 −0.005
𝜎𝐵 = − + = −6.07𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
𝐼𝑥 𝐼𝑧
78.0175
𝜏= = 7801.75 𝑃𝑎 < 𝜏𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑
0.01
Buckling of the Pillar:

We need to find out whether the pillar we are using will buckle or not. Let’s take the weaker axis
which is “x”.

1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.01 × 0.273 = 2.25 × 10−8 𝑚4
12 12
𝜋 2 𝐸𝐼
𝑃𝑐𝑟 =
𝐾𝐿 2
𝜋 2 𝐸 × 2.25 × 10−8
𝑃𝑐𝑟 = = 530.19 𝑘𝑁 > 529.30 𝑁 (𝑠𝑜 𝑖𝑡 𝑤𝑜𝑛′ 𝑡 𝐵𝑢𝑐𝑘𝑙𝑒)
(0.5 × 0.34)2

41
 Bottom Plate + Steel Sheet

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0. 02 𝑚2
𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.0015 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 2800 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.02 × 0.0015 × 2800 × 9.81 = 0.824 𝑁

𝐴𝑟𝑒𝑎 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑆𝑕𝑒𝑒𝑡 = 0. 02 𝑚2

𝑡𝑕𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 𝑆𝑕𝑒𝑒𝑡 = 0.01 𝑚
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 8050 𝑚3
𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.02 × 0.01 × 8050 × 9.81 = 15.79 𝑁

2𝐹𝑦 = 556.498 + 0.82 + 15.79 = 573.11 𝑁

𝐹𝑦 = 286.554 𝑁

2𝐹𝑧 = 78.0175 𝑁
𝐹𝑧 = 39 𝑁
Taking Moment about one Bolt
0.55
2𝑀𝑁,𝑥 = 121.702 − 286.554 × 0.55 + 573.11 ×
2
𝑀𝑁,𝑥 = 60.85 𝑁𝑚

42
 Shear Force & Bending Moment Diagrams

If we look at the bending moment diagram, the maximum moment that exists is at the x-axis
which is 139.656 Nm.

The steel part is of 1cm and Aluminum of 0.15cm. So, net height is 1.15cm
1 1
𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝐼𝑛𝑒𝑟𝑡𝑖𝑎 = 𝐼 = 𝑏𝑕3 = 0.03 × 0.01153 = 3.80 × 10−9 𝑚4
12 12
0.0115
139.656 × 2
𝜎𝑚𝑎𝑥 =
3.8 × 10−9 𝑚4

43
 𝜎𝑚𝑎𝑥 = 211.32 𝑀𝑃𝑎 < 𝜎𝑎𝑙 ,𝑦𝑖𝑒𝑙𝑑 𝑎𝑛𝑑 𝜎𝑠𝑡𝑒𝑒𝑙 ,𝑦𝑖𝑒𝑙𝑑

The Compressive stress and tensile stress will both have the same values. The above material is
aluminum and the one below is steel. So, we have to make sure it doesn’t exceed any of them.

Now let’s check vertical deflection of the Steel plate.

𝑏𝑟𝑒𝑎𝑑𝑡𝑕 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 𝑏 = 0.03 𝑚
𝑕𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 𝑕 = 0.01 𝑚
𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑃𝑙𝑎𝑡𝑒 = 0.55 𝑚
𝐸𝑙𝑎𝑠𝑡𝑖𝑐 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑆𝑡𝑒𝑒𝑙 = 𝐸 = 200 × 109 𝑃𝑎
1 1
𝐼= 𝑏𝑕3 = 0.03 × 0.013 = 2.5 × 10−9 𝑚4
12 12
𝐹𝐿3 573.11 × 0.553
𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 = = = 3.97 𝑚𝑚
48𝐸𝐼 48(200 × 109 × 2.5 × 10−9 )

 Door and Shell

The external Pressure is only 100Pa. So, during acceleration the thrust generated from it
will be considered as negligible. So, we will assume that the acceleration won’t affect the shell
and door as it would affect the chassis and the door.

 Chassis

Cross Member Thickness

The place where the seats are connected with the chassis, we need to find out whether they are
stable or not.
The weight of the steel plate and the reaction forces are acting their as shown in the figure.

44
 𝑊𝑒𝑖𝑔𝑕𝑡 𝑜𝑓 𝑡𝑕𝑒 𝑆𝑡𝑒𝑒𝑙 𝑝𝑙𝑎𝑡𝑒 = 15.79𝑁
𝑅𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝐹𝑜𝑟𝑐𝑒𝑠 = 286.56 𝑁

286.56 × 0.22 + 286.56 × 0.62 + 15.79 × 0.42

𝐹𝑦 = = 294.455 𝑁
0.84

Shear Force & Bending Moment Diagrams

According to the bending moment diagram, the maximum moment is found to be 66.36Nm
We need to find its necessary thickness that will sustain this amount of weight.
𝑀𝑐
𝜎=
𝐼

𝑊𝑖𝑑𝑡𝑕 = 0.1 𝑚

45
Using a factor of safety of 2, we get the allowable stress 125 MPa for steel.

66.36 × 𝑡/2
125 × 106 =
1 3
12 × 0.1 × 𝑡

𝑡 = 5.64 𝑚𝑚

We have used a cross member with 8mm width. So, it won’t deform.

Side of Chassis

As we have mentioned above the door and shell are supposed to behave the same way under
acceleration as they do under steady motion, on the side of the chassis, only the weight of shell is
acting along with the weight of the chassis. So, the reaction forces and maximum bending stress
will be the same as they were in steady state

Battery and Propulsion System

Same goes for the Battery and Propulsion System, as there is no significant effect on them
because of acceleration then they will behave exactly the same as they behave when subjected to
steady motion.

References:
[1] Wenqi Shen, Chantal Parenteau, Raj Roychoudhury and Jeffrey Robbins,
Seated Weight Distribution of Adults and Children in Normal and Non-Normal Positions.
Annual Proceedings /Association for the Advancement of Automotive Medicine
[2]Hazman Seli, Mokhtar Awang, Ahmad Izani Md. Ismail, Endri Rachman,
Zainal Arifin Ahmad, Evaluation of properties and FEM Model of the Friction welded
mild Steel-Al6061-Alumina. Materials Research
[3]All the shear force and bending moment diagrams were made using
beamguru.com

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