SANDY DRIFTERZ, VCET

Madurai, Tamil Nadu.

ROLL CAGE DESIGN WITH DIMENSIONS:
ROLL CAGE ANALYSIS:

FRONT IMPACT REAR IMPACT

Overall Wheelbase=60Inch;Front wheel track=43.2inch;Rear wheel track=50inch;Overall length=80inch

Impact tests are carried out in solid works and the required force are calculated using the relation
F X t = M X V, F-Force, t-Time, M-Mass, V-Velocity.
ROLL CAGE ANALYSIS:

SIDE IMPACT:
 Engine Specification:

Engine is Model 20 305 cc Briggs and Stratton Engine

Engine specs:

Model Number I/C

Type 202400
Displacement 305
Bore 3.120
HP vs rpm Graph
Stroke 2.438
Compression Ratio 8.0 to 1
Horse power 10HP
RPM 3600rpm
Gross torque 14.50 Nm
POWER TRAIN :

V Ra Rr Rg Tr
0 0 33.85 1128.5 1162.35
5 0.208 35.35 1128.5 1164.06
10 0.832 37.461 1128.5 1166.57
15 1.812 39.266 1128.5 1169.57
20 3.328 41.072 1128.5 1172.9
25 5.2 42.877 1128.5 1176.57
30 7.488 44.683 1128.5 1180.671
35 10.192 46.488 1128.5 1185.18
40 13.312 48.294 1128.5 1190.1
45 16.488 50.09 1128.5 1195.44
50 20.8 51.905 1128.5 1201.2
55 25.168 53.71 1128.5 1207
60 29.952 55.515 1128.5 1207.37
 POWER TRAIN :

Speed obtained at a particular gear for various rpm are tabulated and plotted in graph
as follows
 BRAKE:

Force in Brakepad 300N

Formula used:
Force in mater cylinder 2100N

Pedal ration 07:01 Fmc = Fbd*(L1/L2

Pressure in Master cylinder 6.68 N/mm2 Pressure = (FBP/Area of master cylinder)
Pmc = Par
Force in Caliper 2100N
Fcal = Fmc*A
Clamping Force 4200N Fclamp = 2*Fcal
1302N
Frictional force Ffriction = Fclamp * µbp
Torque 139N
Tr = Ffriction*Reff
Ft = Tr/radius (rolling)
Force at tyres 500N(approx)
ƩF = Ft + Ft + Ft + Ft
Braking force 1998.07N (2000N approx) Brake Efficiency = Brake force / weight
Brake Efficiency 81% of vehicle
Deceleration 7.38 m/s2
Deceleration = ῃ*g
U2-V2 = 2as
Stopping Distance 17.5m
V = u + at
Stopping Time 2.13s
STEERING:
STEERING:

Inner wheel turn angle vs outer wheel turn angle:

Relation between inner and outer wheel angle:

cot φ – cot Θ = c/b

 SUSPENSION:
Front Suspension: Mac pherson stud type
WHEEL TRAVEL DATA(mm) Wheel
Motion ratio 2.51 2.63
Rate(Kg/mm) Wire Diameter(mm) 8
from Reboun Bump -
Heigth -ECIE(mm) 215 Spring Rate(kg/mm) 6.21
Bump d Metal Solid 38
Margin(mm)
Rbnd-
GVW to Top End 82 Solid height 56
45 45 45 Free 88
coil Bottom Allowed Shear
Kerb to 82 Stress(N/mm^2)
490.811
34 38 34 Diameter(mm) End Coil to Coil @Bump 3.2
Modulus of Active
Over load to Mean 82 80000
Rigidity(N/mm^2) coil 37.6
26 47 47
Coil Pitch(mm)
Bump to Rbnd Active 6 UTS(kg/mm^2) 190 In-Active
90
coil 4.3
Metal to Rbnd No of coils SAE
90 In-Active 0 Material
9254 Deflection/Turn(mm) 26
plain
Total 6 End type
&Open Weight(kg) 3.63
Coil to 1.137
106.5 Spring Index(7-9) 10.5
Coil Whal's Stress C Factor 5
Deflection(mm)
Unladen(kerb) -15 Natural
GVW to Actual 106.5
frequency 1.58
Laden(overload) 2 Swing arm
wire Diameter(mm) 8
length 300
Front Wheel condition Wheel travel(mm) Spring Strut
Height(mm) Travel(mm) Load(kg) Stress(kg/mm^2) Travel(mm) Height(mm)
Free 54 234 -54 0
Rebound 45 67 112.95 1037 512 112.95 300.95
Kerb -16 220 -40 86 42 -40 454.1
GVW 0 180 0 335 166 0 413.9
Overload 8 160 20 460 227 20 393.8
Bump 45 67 112.95 1037 512 112.95 300.95
Metal 45 67 112.95 1037 512 112.95 300.95
Solid 32 56 124 661 327 125 289.1
 SUSPENSION:
Rear Suspension: Mac pherson stud type
WHEEL TRAVEL DATA(mm) Wheel
Motion ratio 2.51 3.42
Rate(Kg/mm) Wire Diameter(mm) 9
Spring Bump -
from Heigth -ECIE(mm) 215 8.4
Bump Rebound Metal Rate(kg/mm) Solid 38
Margin(mm)
Rbnd-
GVW to Top End 92 Solid height 81
48 48 48 Free 88
coil Bottom Allowed Shear
Kerb to 92 417.8
Diameter(mm) End Stress(N/mm^2) Coil to Coil @Bump 3.2
39 43 39
Modulus of Active
Over load to Mean 92 Rigidity(N/mm^2)
80000
26 49 49 coil 37.6
Coil Pitch(mm)
Bump to Rbnd Active 8 UTS(kg/mm^2) 190 In-Active
96 coil 4.3
Metal to Rbnd In- SAE
96 No of coils 0 Material
Active 9254 Deflection/Turn(mm) 26
plain
Total 8 End type
&Open Weight(kg) 3.63
Coil to 1.157
106.5 Spring Index(7-9) 9.2
Coil Whal's Stress C Factor 8
Deflection(mm)
Unladen(kerb) -12 Natural
GVW to Actual 106.5
frequency 1.34
Laden(overload) 1
wire Diameter(mm) 9 SWIMG ARM
LENGTH 320
Front Wheel condition Wheel travel(mm) Spring Strut

Height(mm) Travel(mm) Load(kg) Stress(kg/mm^2) Travel(mm) Height(mm)

Free 63 234 -63 0 -63
Rebound 45 67 112.95 1402 546 112.95 300.95
Kerb -12 209 -29 207 81 -29 443.3
GVW 0 180 0 454 176 0 413.9
Overload 5 167 13 566 220 13 400.5
Bump 45 67 112.95 1402 546 112.95 300.95
Metal 45 67 112.95 1402 546 112.95 300.95
Solid 32 56 124 895 348 125 289.1
 Cost report
PRE FINAL ROUND COST REPORT
Materials Processes Fasteners Tooling Total
Brake System Rs. 8,000.00 Rs. 1,600.00 Rs. 2,450.00 Rs. 1,200.00 Rs. 13,250.00
Engine Rs. 34,000.00 Rs. 500.00 Rs. 0.00 Rs. 0.00 Rs. 34,500.00
Frame & Body Rs. 5,500.00 Rs. 2,000.00 Rs. 1,300.00 Rs. 2,500.00 Rs. 11,300.00
Instruments & Wiring Rs. 3,500.00 Rs. 500.00 Rs. 500.00 Rs. 800.00 Rs. 5,300.00
Miscellaneous, Fit & Finish Rs. 5,400.00 Rs. 800.00 Rs. 600.00 Rs. 1,250.00 Rs. 8,050.00
Steering System Rs. 3,700.00 Rs. 1,250.00 Rs. 1,800.00 Rs. 1,500.00 Rs. 8,250.00
Suspension & Shocks Rs. 7,690.00 Rs. 2,350.00 Rs. 1,800.00 Rs. 3,400.00 Rs. 15,240.00
Wheels & Tires Rs. 24,000.00 Rs. 3,700.00 Rs. 3,400.00 Rs. 2,000.00 Rs. 33,100.00
Drivetrain Rs.7000.00 Rs.2200 Rs.1500.00 Rs.2000.00 Rs.12700.00
Safety Rs.40000 0 0 0 Rs.40000.00
Total Vehicle RS.1,31,790.00 Rs. 12,700.00 Rs. 11,850.00 Rs. 12,650.00 RS.1,81,690.00

COST REPORT

Rs. 40,000.00
Rs. 30,000.00
Rs. 20,000.00
Rs. 10,000.00 Total
Rs. 0.00
Fasteners
Materials

Materials Processes Fasteners Tooling Total

S.NO SPECIFICATION TEST DESCRIPTION ACCEPTANCE CRITERIA TEST

1. Rear frame stiffness Fix chassis side of frame, load Minimal deflection. Validated
&measure displacement

2. Torsion Analysis Fix Rear, apply equal & opposite Minimal deflection. Validated
loads.

3. Finite Element Analysis Apply Loads, constraints and measure Maximum Factor Of Safety Validated
stresses. (>2)

4. Suspension Travel Move wheels through maximum At least 3” of travel in bounce Validated
range of motion & jounce

5. Upright Failure Maximum Loading Conditions. No permanent Deformation. Validated

6. Tie Rod Failure Apply normal load until failure Max Allowed Force - 36000N Validated

7. Braking Test Apply Strong Braking Force Able to Lock all 4 Wheels Validated

Design report , failure analysis are included in mail.

Thank you