BAJA Presentation MIT Bellatores

7/27/2019 BAJA Presentation MIT Bellatores

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3D VIEWS



TECHNICAL SPECIFICATIONSENGINE

Type

Displacement c

Max. Torque N

Max Power , hp

TRANSMISS

Mahindra Alfa G

4 Forward- 1 re

STEERING

Rack And Pinio

SUSPENSIO

Front

Rear

BRAKES

Hydraulic Disc B

DIMENSION

Length (inches)

Width (inches)

Height (inches)

Weight Distribution (Total = 250kg)

51.2 KG

LEFT

76.5KG

48.8KG

RIGHT

73.5 KG

FRONT

REAR

WEIGHT

CENTER OF

WHEEL

Kerb Weight

Gross Weight

Front (OD x Wi

Rear (OD x Wid

CG wrt centreof firewall (mm

Y

Z

X

54”

Wheel Track

61” Wheel Base



ROLL CAGE AND ERGONOMICSErgonomic Conditions

Parameter Std. Value Our Values Parameter

Angle at elbows 125⁰-140⁰ 132˚ Steering Wheel Dia.( mm)

Angle at Knees 120-⁰150⁰ 130˚ Angle of Steering Wheel

Angle at Back 8⁰-15⁰ 10 ̊

Salient Features

Adjustable Seat

Rulebook Conformance

Roll Cage Features

Parameter Value Parameter

Total Number of welds 81 Tube Outer Diameter mm

Weld Length 7 m Thickness of tube (mm)

Tubing Length 30.25 m Weight of tubing (Kg)

Parameter Allowable Value

Maximum vehicle width (inches) 64

Maximum vehicle length (inches) 108

Minimum firewall width at 27 inches above seat 29

Material used Steel alloys

Vertical distance of S.I.M. from seat (inches) 8 -14

Firewall angle in degrees Maximum 20

Firewall triangulation members -Upper

LowerLess than 5 inches

Angle- Greater than 20 deg

F.B.M. angle Less than 45 deg

Reach Bubble

Binocular Vision



FINITE ELEMENT ANALYSIS

FRONTAL IMPACT SIDE IMPA

Weight of

vehicle

300 kg Impact

time(sec)

0.2

Maximum

Force (kN)

23.25 Maximum

Force (g)

7.9

Weight of

vehicle

Maximum

Force (kN)

Weight of

vehicle

300 kg Impact

time(sec)

0.2

Maximum

Force (kN)

23.25 Maximum

Force (g)

7.9

Weight of

vehicle

Maximum

Force (kN)

Maximum Equivalent Stress (MPa) 217.1

Maximum Deformation (mm) 2.3

Factor of Safety 2.2

Maximum Eq

Maximum De

Factor of Safe

Maximum Equivalent Stress (MPa) 137.4

Maximum Deformation (mm) 5.34

Factor of Safety 3.35

Maximum Eq

Maximum De

Factor of Safe

ROLL OVEREAR IMPACT



Front Suspensions

Rear Suspensions

Vehicle Dynamics

Parameter Value Parameter Value

Toe in 2.0 deg Height roll

center

10.64 in

Camber gain 2.3 deg Rolling force 1.76g

Caster gain 7.3 deg Ground Clarence 33 cm

Weight transfer 111.3kg King pin angle 5deg

Static camber set

zero

zero Scrub radius 2.53 in.

Suspension Specifications

Parameter Front RearLength of Spring 300 mm 250 mm

Total Length 450 mm 450 mm

Max.travel spring 192 mm 96.8 mm

Spring Stiffness 40.23N/mm2 31.54N/mm2

Types Square grounded Square grounded

Roll Centre Height 10.4 in. 10 in.

SUSPENSIONS

Boundary conditions Front - 3g bump



STEERING SPECIFICATIONS

Parameter Value Parameter Value

Length of rack 144 mm Pitch circle diameter 26 mm

Ratio rack and

pinion

12:1 Moment ratio 12:1

Axial pitch of

rack bar

6mm No. of universal joints 2

Column

inclined

45 deg Teeth on rack 36

No. of tie rods 2 Length of tie rod 10.18

inch

STEERING W

Parameter Va

Angle outer 4

Angle inner 3

Wheel

angle lockto lock

47

Steering

ratio

9.7

BRAKES CONFIGURATIONS

Parameter Type/value Parameter Value

Disc Honda Dazzler Leverage 4.75

Disc outer Diameter(mm) 20 Pedal force (N) 160

Braking Torque(Nm) 115.08 Dynamic Weight Transfer 61.92 kg

Caliper Suzuki GS 150

R

Pulsar 220 Stopping Distance (m) 17.6

Diameter of piston(mm) 26 25.6 Radius of gyration(m) 0.198 m

Tandem Master Cylinder Maruti 800 Moment of inertia(kg.m2) .390

Diameter of piston(mm) 20 Temperature rise(deg c) 37

BRAKE CIR



Input Parameters

POWER TRAIN

Optimization

Gear Speed (Kmph) Max gradient

1st (31.45) 12.2 26.7⁰

2nd (18.7) 20.5 12.7⁰

3rd (11.4) 33.7 5.16⁰

4th (7.35) 52.3 0.60⁰

Rev (55.08) 7

Tire Size 23” Tire Size 25”

Gearbox Acceleration

(m/s²)

Top Speed

(Time)

Acceleration

(m/s²)

Top Speed

(kmph) (s)

Mahindra Alfa

pickup

4.46 52.3(22) 3.97 57.3(36)

Mahindra Alfa

passenger

3.36 67(32) 3.07 72(42)

Tata Ace zip 3.52 63(30) 3.17 68(38)

Max Power = 10 HP@3250 rpm Rolling Coefficient = 0.1

Max Torque = 19.66Nm@2800 rpm Drag Coefficient = 0.9

Tire Rolling Radius = 0.286 m Max Gradient = 26.7⁰

Gear Ratios (Alfa pickup)Coupling Dimensions Length(mm)

Diameter of shaft 25.4

Diameter of outer hub 50.8

Length of hub 38.1

No of bolts 4



BODY SAFETY & ELECTRICALS

• 5-point safety harness with arm restraints.

• Fire Resistant Driver Suit, gloves, helmet, te

• Cockpit designed to keep driver safe during

• Vehicle designed to facilitate ease in driver

• Polymer based side panels; do not project s

• Provision of drip pan and splash shield.

• Provision of fire extinguisher and kill switch

• Independent disc hydraulic braking systems

• Engine Overheating alarm.

• High crumple in the front zone.

• Proper asbestos insulated fuel tank.

• Pressure differential valve to assist breaking

SAFETY SALIENT DRIVER’S SAFETY

Parameter Allowable Value Designed Value

Distance of R.H.O. above helmet(inches)

Minimum 6 8

Distance of S.I.M. from

driver’s body (inches)

Minimum 3 8.7

Position of Driver’s feet Behind the plane of AF(RL) and RF(RL)

Firewall thickness (inches) Minimum 0.02 0.2

Safety harnesses, clothing

and restraintsS.F.I. Specifications

Provisions made

accordingly

Binocular VisionELECTRICA



MANUFACTURING PROCESSES & TOOLS

Component/Operations Machine

Wishbones ARC Welding/TIG

Hub CNC Lathe

Spacer Purchase

Roll Cage ARC Welding/TIG

Material Testing U.T.M. ; Brinell Hardness Tester

Flange Gearbox Outsource

Pipe Bending, Cutting, etc. PBM

Hacksaw

Pipe cutting machine

TECHNICAL PARTS LIST OVERALL WEIGHT COST



TECHNICAL PARTS LIST. OVERALL WEIGHT COST

ELEMENTS/ESTIMATE FINANCINGS.N

. System Description Particulars Cost

1. Raw Material & Fabrication

a) Tubes (80Kg) @ Rs 100/ Kg 8000/-

b) Labour Cost At Institute 00

c) Welding Cost At Institute 00

d) Painting Cost At Institute 00

Total (A) 8000/-2. Power Train

a) Engine By SAE- India 35000/-

b) Transmission System To be purchased 36000/-

c) Miscellaneous Couplings, etc 10000/-

Total (B) 81000/-

3. Suspension & Steering System

a) Shock Absorbers (4 Nos.) @ Rs 3500 / item 14000/-

b) A- Arms (4 Nos.) @ Rs 1000/ item 4000/-

c) Uprights (4 Nos.) @ Rs 4000/ item 16000/-

d) Rack & Pinion To be purchased 10000/-

e) Accessories To be purchased 5000/-

Total (C) 49000/-

4. Brakes & Tires

a) Brakes To be purchased 12000/-

b) Tires (4 No's) @ Rs 10000/ tire 75000/-

Total (D) 87000/-

5. Miscellaneous 30,000/-

Total (E) 30,000/-

TOTAL COST (A+B+C+D+E) 255000/-

Lathe Drilling

Arc WeldingHardness Teste

Gas welding

Impact testing

FACILITIES AVAI



Roll cage design &Analysis

Akshay Poal

SiddharthShrivastava

Sudheerkumar

Rahul Awate

Transmission

ShreyanshSharma

Rohan Saxena

Pratik Mishra

Kumaril Bhatt

Steering

DarshanUpasani

Sachin KumarSingh

HarshKhardekar

Ankit Kalore

Suspension

AkshatSharma

Abdul Faizalkhan

Asmit Jain

AkshayUpadhyay

Brakes

AshrayPawar

ShantanuDwivedi

VishwasParmar

Sharat Reddy

Shrey Arodia

Faculty Advisor : Mr. Amit Kumar Marwah

Team Captain : Rahul Awate Vice Capt

TEAM ORGANISATION



PROJECT PLAN

Vehicle

30/Nov

Technic

05/Jan/

TASK No. Of Day(s) Dates

Interviews 5 2/3/2013

Task submissions & HOD determination 2 7/3/2013

Prilimanary Meetings 7 9/3/2013

Workshops And Member Training 16/3/13

Design & Analysis

Primary Design And Analysis 10 10/4/2013

Modification & Analysis 8 20/4/13

Tech. Assessment & Calculation 15 28/4/2013

Semester Exams 30 13/05/13 Design Modification after Analysis 10 20/07/13

Verification & Proofing Of Final Calculation 4 30/06/13

Innovation And USP 3 3/7/2013

Saftey Features 3 6/7/2013

Final Design Modifications 4 9/7/2013

Presentation Drafting 7 13/07/13

Presentation Mock Practice 3 20/07/13

Virtual Round 4 24/07/13

Virtual results 15 15/08/13

Design Report 5 20/08/13

Fabrication

Material Procurement & Sponsorships 10 30/08/13 Prototype Modelling 1 9/9/2013

Fabrication Of Rollcage 10 10/9/2013

Sub Assembly Delivery & Installation 10 20/09/13

Suspension & A arm 5 30/09/13

Power Train 5 5/10/2013

Steering 3 10/10/2013

Engine And Tyre Mounting 4 13/10/13

Elecrical System 3 17/10/13

Final Assembly+ Accessories 6 20/10/13

TESTING

1st Build test and Modifications 10 1/11/2013

2nd Build test and Modifications 10 10/11/2013

Final test Drive 4 20/11/13

Technical Ins ection 1 30/11/13



No Item Potential mode of

failure

Severity

(S)

Causes of Failure

Occur

rence

(O)

Detec

tion

(D)

Risk Priority

Number

(RPN)=

S*O*D

Recommend

Actions

1. Roll cage Deformation in rollcage

due to weld failure

8 Heavy impact or

improper welding

2 9 144 Better mater

efficient desig

2. Brake system Failure of brakes 7 Air pocket in brakelines

5 7 245 Bleeding poinTMC

3. Suspension

system

Failure of ball joint 7 Impact Loading 4 8 224 Efficient posit

lubrication of

4. Transmission

System

Bending of drive shaft 6 Hitting of drive shaft

to frame at full

rebound

3 8 144 Validating the

movement of

at rebound co

5. Engine air

intake

Clogging of air filter 4 Excessive dust

entering

6 7 168 Rerouting of

from above t

6. TMC Failure of push rod 2 Restriction to

motion of pushrod

8 8 128 Pushrod shou

adequate D.O

7. Engine Fouled Spark Plug 5 Spark Plug is dirty or

broken

3 3 45 Approximate

plug and late

at regular int

8. Wheel Axle Bends in axle 7 Excessive load on

wheel caused by

heavy rider or

performing tricks

3 4 84 Use a stronge

and add a wa

max. weight

DESIGN FAILURE MODE EFFECT & ANALYSIS (DFMEA)



Test Plan

Test

ID Test Segment Test Description Target

Requirements

Our Valu

1. Brake system

Stopping Distance:

The vehicle is to be loaded on a jack and front wheels and spring are removed.Damper is mounted in the

designated position and point of maximum designed travel is marked. Hub is moved upwards manually till

the point of maximum travel. Difference between the initial and final position of hub is to be noted.

15-20m 17m

2. Suspension

Travel of spring:The vehicle is to be loaded on a jack and front wheels and spring are removed.Damper is mounted in the

designated position and point of maximum designed travel is marked. Hub is moved upwards manually till

the point of maximum travel. Difference between the initial and final position of hub is to be noted.

5 cm 5.4 cm

3. Transmission

Maximum speed:

Vehicle is to be loaded on a jack. Transmission is shifted to final gear and full throttle is given for 20

seconds.Tachometer is to be held at the wheels and maximum reading is noted. Speed is calculated by

using 0.051*reading*radius of wheel.

55 kmph 52 kmp

4. SteeringTurning radius:

Vehicle is to be taken to a surface with loose soil and a circle with steering wheel locked at full travel is to

be negotiated. The distance between the two diametrically opposite points is to be measured.< 3.5m 3.19m

5. Roll Cage

Weld Test:

The welded joint is to be taken and tested on a Universal Testing Machine. The failure is to be observed.Another method is to take the welded joint and impact with multiple hammer blows until failure. Failure

of weld or material is noted.

<= 10mm 5.7mm

6. VehicleCentre of gravity: Vehicle is kept on balancing machine and load on front & rear axle is noted. For finding

height vehicle is lifted from front axle and load transfer is noted .>15,<25

7. Vehicle Internal & External Body dimension 80,60,55 88,62,6

8. Vehicle Ground Clearance, Approach 8”-10” 10”

9. Transmission Maximum Gradient :

Two planks are to be kept at 15 degrees initially. Increase angle by 5 degrees till the vehicle does not take

off on gear oneataround 2800-3200 engine rpm. The previous angle is to be noted.

>20 26.7˚

10. Vehicle Vehicle weight 220 kg 250 kg

DESIGN VERIFICATION PLAN & REPORT

BAJA Presentation MIT Bellatores

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