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DAYANANDA SAGAR COLLEGE OF ENGINEERING BANGALORE

Team Kashpiers "Baja 2013"

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•SAE Baja is an Inter-colligate off road racing competition where the top engineering colleges in India successfully fabricate and race there all-terrain vehicles. •The competition has various automotive giants like Mahindra, General motors etc. powering the event. •The contest challenges each team to function as a firm whose objective is to design, fabricate, market and race off their vehicles that would be evaluated on a variety of manufacturing angles by various professionals from the sponsoring automotive companies.

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Page 1: Team Kashpiers "Baja 2013"

DAYANANDA SAGAR COLLEGE OF ENGINEERING BANGALORE

Page 2: Team Kashpiers "Baja 2013"

TECHNICAL

FEATURES

Page 3: Team Kashpiers "Baja 2013"

VIEWS

ISO SIDE

TOP FRONT

Page 4: Team Kashpiers "Baja 2013"

ROLL CAGE DESIGN

MATERIAL

TUBINGS

SAE 1018

MILD

STEEL

WALL THICKNESS 3mm

COCKPIT

DIMENTIONS

1000*700m

m2

LENGTH 84.52 in

HEIGHT 31.49 in

WIDTH 61 in

No. OF WELDS 44

WELD LENGTH 46.2 in

TUBE Od 27mm

TOTAL WEIGHT 70 kg

Page 5: Team Kashpiers "Baja 2013"

FRONT ANALYSIS

Material AISI 1018 Steel

Density 7.7 Kg/m^3

Yield Strength 386 MPa

Tensile Strength 634 MPa

Poisson's Ratio 0.27-0.3

Material Specification

Analysis Results

Maximum

Stress

124.88 MPa

Maximum

Displacement

1.4411 mm

Acceleration 3g

Page 6: Team Kashpiers "Baja 2013"

REAR ANALYSIS

Material AISI 1018 Steel

Density 7.7 Kg/m^3

Yield Strength 386 MPa

Tensile Strength 634 MPa

Poisson's Ratio 0.27-0.3

Material Specification

Analysis Results

Maximum

Stress

269.557 MPa

Maximum

Displacement

4.4239 mm

Acceleration 3g

Page 7: Team Kashpiers "Baja 2013"

SEAT AND ENGINE ANALYSIS

Material AISI 1018 Steel

Density 7.7 Kg/m^3

Yield Strength 386 MPa

Tensile

Strength

634 MPa

Poisson's Ratio 0.27-0.3

Material Specification

Analysis Results

Maximum

Stress

19.4926 MPa

Maximum

Displacement

0.3291 mm

Load 146 kgf

Page 8: Team Kashpiers "Baja 2013"

SIDE ANALYSIS 1

SIDE ANALYSIS 2

ROLL OVER ANALYSIS ROLL OVER ANALYSIS

Page 9: Team Kashpiers "Baja 2013"

POWER TRAIN ENGINE SPECS

• Briggs and Stratton • Model 205432/205332 • Power = 10HP • Compression Ratio= 8:1 • Torque = 18.6Nm at

2600rpm • 305 CC • Four Stroke

Gear R Overall ratio Max speed kmph Tractive force (N) Acceleration(m/s*s ) Gradeability%

1st 31.48:1 12.42 1798.66 5.45 45.56

2nd 18.7:1 20.91 1068.46 3.237 23

3rd 11.4:1 34.3 651.358 1.97 10.12

4th 7.35:1 53.2 419.95 1.27 2.97

rev 55.08:1 7.1 3147.09 9.5366 87.2134

For TIRE DIAMETER 22 inch, max speed at red line rpm is 48.77kmph For TIRE DIAMETER 24 inch, max speed at red line rpm is 53.2kmph Therefore selecting 24 inch diameter for the rear tire : Taking, N = Transmission Efficiency = 0.8 Mo =Gross mass of the vehicle = 330 kg Fr=Coefficient of rolling friction for vehicle on dirt track = 0.1

TRANSMISSION:MAHINDRA CHAMPION ALFA

Page 10: Team Kashpiers "Baja 2013"

CHAIN COUPLING

MATERIAL MS1024

PITCH 12.7mm

NO OF TEETH 15

PITCH DIA 62mm

VELOCITY 8m/s

REQUIRED

PULL

2138N

ALLOWABLE

PULL

1137.5

NO OF

STRANDS OF

THE CHAIN

2

LENGTH OF

CHAIN

1194mm

MAX

DIFFERENCE

BETWEEN 2

CENTERS

550mm

DIAMETER

REAR AXLE

CALCULATIO

NS

MATERIAL SOLID STEEL

8620

TORQUE=F

OS x GERA

RATIO x

MAX

ENGINE

TORQUE

T= 2x 55.08x

19

= 2093.04 N-

m9

T=(p/16) x t

xdo3

MAXIMUM

PERMISSAB

LE SHEAR

STESS

“T”

T=897x 10^6

N/m2

T=2093.04

Nm

2093.04=(3.14

/16)x 897x

10^6 Xdo3

Do3=1.19x 10-5

Do=0.0228

Do= 22.8mm

MAX SHEAR

STRESS

DUE TO

ENGINE

TORQUE

897/2= 448.5

N/mm2

TRANSMISSION Rpm vs Speed

Rpm vs Tractive effort

Page 11: Team Kashpiers "Baja 2013"

TYPE : OUTBOARD

UNEQUAL(FRONT) DOUBLE

A ARMS WITH ADJUSTABLE

CAMBER USING BALL

JOINTS

SHOCK ABSORBERS: COIL

OVER DAMPER

ROLL CENTRE HEIGHT : 4”

CAMBER ANGLE : 0

DEGREES

CASTOR ANGLE : +5

DEGREES

CASTOR TRAIL : 2.43

cm

TOE : 0

DEGREES

SPRING MATERIAL : CHROME VANADIUM STEEL

FRONT REAR

SPRING

STIFFNESS

7.8956 N/mm 11.8435

N/mm

DAMPING

FACTOR

0.3 0.3

DAMPING CO

EFFICIENT

0.377NS/mm 0.565NS/mm

DAMPED

NATURAL

FREQUENCY

1.9078 Hz 1.9078 Hz

DESIGN

WIRE DAIMETER 10 mm 12

MEAN COIL

DIAMETER

80 mm 96

NO OF TURNS 25 20

FREE LENGTH 460.5 mm 454.5

PITCH 17.62mm 21.525mm

SUSPENSIONS

Page 12: Team Kashpiers "Baja 2013"

SUSPENSION ANALYSER

FRONT TOP A-ARM ANALYSIS

DIVE CASTE

R Lt.

CASTE

R Rt.

CAMBE

R Lt.

CAMBE

R

Rt.

RC Lt/

RT,in

LT

RC Lt/

RT,in

RT

RC

Ht,

In LT

RC Ht,

In RT

SCRU

B

In LT

SCRU

B

In RT

.000 3.951 3.951 .000 .000 .000 .000 3.997 3.997 .000 .000

-.500 3.955 3.955 .668 .668 .000 .000 4.860 4.860 .127 .127

-1.00 3.960 3.960 -1.098 -1.098 .000 .000 5.704 5.704 .361 .361

-1.50 3.966 3.966 -1.436 -1.436 .000 .000 6.504 6.504 .659 .659

-2.00 3.975 3.975 -1.737 -1.737 .000 .000 7.367 7.367 1.010 1.010

Page 13: Team Kashpiers "Baja 2013"

STEERING > MODIFIED MARUTI 800 RACK

AND PINION

WHEEL TRACK 67in

WHEEL BASE 58in

STEERING AXIS

INCLINATION (SAI)

12°

SCRUB RADIUS 7.8mm

ACKERMANN ANGLE 17 °

TIE ROD LENGTH 38.29 in

INNER STEERING ANGLE 44°

OUTER STEERING ANGLE 31.5°

TURNING RADIUS 3.38m

STEERING RATIO 9.7:1

STEERING WHEEL

LOCK TO LOCK

610°

STEERING

Page 14: Team Kashpiers "Baja 2013"

Brake Components & Remarks

Components

• All 4 Disc combination used to

achieve 4 Wheel Lock .

• Disc Used – Apache RTR 180

(Rear)

• Caliper Used – 3Apache RTR

180 (Front) and 1 Honda

Aviator

• Master Cylinder Used – Maruti

800 Bosch Tandem Master

Cylinder (OEM)

• Aluminum Brake Lines,

Hydraulic Brake hoses, Banjo

bolts etc.

Remarks

• The Disc and Calipers being

used are the same as previous

year. The reason being its

Reliability and to ease up the

Budget. (Spares will be bought

in case any malfunctions.)

• This particular combination of

Calipers is chosen due to its

Ease of Mounting Bleeding

points on top.

• Bosch Tandem Master cylinder

is used because of its

Compatibility with the Calipers

and BAJA recommends use of

OEM.

• Diagonal Braking Circuit Split

used so that braking power is

available on both Axles in case

one Circuit Fails.

Page 15: Team Kashpiers "Baja 2013"

BRAKING SYSTEM & CIRCUIT SPECIFICATION

S

VALUE

DISC DIAMETER

Outer\inner

200mm/170mm

CAPILER

PISTON/MASTER

CYLINDER

DIAMETER

20mm/20mm

BRAKE FORCE (N) 2750.55 N

STOPPING

DISTANCE

13.516 meter

(54.0 Km/hr)

STOPPING TIME 1.8 +0.3+0.75 sec

(54.0 Km/hr)

DECELERATION 8.3235m/s^2

DECELERATION avg. 5.26m/s^2

PEDAL FORCE 40 kg

SPECIFICATIONS VALUE

PEDAL RATIO 7:1

STATIC AXLE LOAD

(FRONT\REAR)

582.714N/

2654.6N

DYNAMIC AXLE LOAD

(front/rear)

896N/

2341N

WEIGHT TRANSFER 808.48N

BREAKING TORQUE 582.38N-m

TRACTION FORCE ON

SLOPE

2289.117N

CYLINDER PRESSURE 7.876MPa

MASTER CYLINDER

LOSSES

0.125cc

Page 16: Team Kashpiers "Baja 2013"

ELECTRICALS

BATTERY

12 V

HEAD LAMP

15W

HORN

10W

REVERSE

LIGHT

3W LED

REVERSE

ALARM

10W

BRAKE

LIGHT

5W

Page 17: Team Kashpiers "Baja 2013"

SAFETY & ERGONOMICS

• 2 Kill switches (ski do type) are fitted at the dashboard and the top right corner of the vehicle.

• SFI & FIA Certified Race Suit, 5 Point Seat belt. Certified

Motocross Helmet, Gloves, Neck Brace, British standard Goggles & Arm Restrainers.

• The figure below suggests that the driver can exit & enter

from the vehicle conveniently within 5 seconds as suggested in the rule book.

BINOCULAR VIEW

Page 18: Team Kashpiers "Baja 2013"

DESIGN FAILURE MODE EFFECTS ANALYSIS PART FUNCTION FALIURE MODELS PRECAUTIONS

ROLL CAGE TO PROTECT THE DRIVER WHEN MATERIAL

REACHES THE ULTIMATE

STRESS VALUE

USE OF AISI 1018 STEEL

HAVING YEILD STRESS

VALUE OF 386 MPa

ENGINE TO GENERATE POWER • SPARK PLUG FAILURE/

IMPROPER FUNCTIONING

• OLD FILTER

• REGULAR CHECK OF

SPARK PLUG

• FILTER CHANGE

TRANSMISSION TO TRANSMIT POWER

FROM ENGINE TO WHEELS

IMPROPER LUBRICATION/

UNEXPECTED LOAD

USE OF ISO GRADE OILS.

SUSPENSION TO ABSORB SHOCKS WHEN COIL REACHES TO

SOLID LENGTH

PROPER ASSUMPTIONS IN

DESIGNING.

STEERING TO STEER THE VEHICLE BREAKING OF TIE ROD TIE ROD PLACED BEHIND

THE FRONT A-ARMS

BRAKES TO REDUCE THE SPEED

WHEN REQUIRED AND TO

PANIC STOP

• CIRCUIT FALIURE DUE

TO LEAKAGE

• WORNOUT BRAKE

PADS

• BLEEDING THE

BRAKES BEFORE

EVERY RUN

• REGULAR CHECK AND

REPLACEMENT

WHEELS TO PROVIDE GOOD

TRACTION

• INAPPROPRIATE AIR

PRESSURE

• PUNCTURE/TEAR

• CHECK THE AIR

PRESSURE AT EACH

REFUEL

• SPARE TIRES

Page 19: Team Kashpiers "Baja 2013"

Vehicle Statistics

Number of wheels 4(not in a straight line)

Width 64”

Length 108”

Driver’s weight & height 113.4kg & 6’3”

Top speed 60km/hr

Engine Statistics

Required engine B&S

Displacement 338 cc

Power 11hp/8 kW

Spark plug RC12YC

Idle speed 1300+/-100

Air filter inlet diameter 22mm

Governor setting 3600 r.p.m(max)

Fuel tank capacity 6 litre

Exhaust System

Muffler’s Back pressure 450mm of water column

Exhaust pipe Any length

Exhaust pipe clearance

dimension

100mm(min.)

Battery Requirements

Battery 12V, 44Ah

Transponders

Orientation

Vertical to frame

Location 24” above the track(max.)

Roll cage material specifications

Outer diameter 1”(min.)

Wall thickness .12”

Carbon content .18%

Miscellaneous

Driver’s exit time 5 seconds

Firewall thickness .020”

Fire extinguishers 1 litre(min.)

Shoulder harness mounting 7” to 9”

Drip pan diameter 8”

Head restraints

Minimum area 36sq inches

Density of padding 50-100kg/m^3

Minimum thickness 1.5”

Head clearance from seat 41”

Head clearance from helmet 6”

Rule Book Compliance

Page 20: Team Kashpiers "Baja 2013"

2012 2013

Anti Ackerman steering Ackerman steering geometry

Engine Mounting: Direct Coupling Chain Sprocket is used

A Bumper was provided No bumper is provided

Bolt and nut pivot was used Ball Joint pivot is used

Equal and Parallel A-Arms Unequal and parallel A-Arms

Tie-rod was in front of the A-Arms Tie-rod is behind the A-Arms

Tyre size: Front 21in, Rear 22in Tyre size: front 22in, Rear 24in

VARIATIONS IN DESIGN

Page 21: Team Kashpiers "Baja 2013"

VARIABLE CHAMBER MECHANISM - The variable camber mechanism is a

modification in the front suspension design which will allow us to vary the camber angle at will. This is done through using adjustment bolts which will help vary the distance between the upper knuckle joint and the chassis. Camber can be varied in test runs and the optimum camber can be decided for the particular condition.

INDEPENDENT FENDERS-The fender is a removable attachment to the A-arms of the suspension which help to block dirt & sludge away from the driver. It is mounted on the A-arms using pipe brackets hence avoiding drilling of any holes. The assembly is spring loaded allowing it to undergo slight deflections and not making it rigid and prone to failure.

INNOVATIONS

Page 22: Team Kashpiers "Baja 2013"

MARKETING

&

SPONSORSHIP

Page 23: Team Kashpiers "Baja 2013"

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

• A non-profit organization based at Detroit, USA

• Working with a mission to enhance human capability of Mobility Engineering professionals – air, land and sea.

• It strives to achieve it through • Establishing engineering standards

• Professional Development Programmes

• Capturing the latest technology and trends

• Research publications

• Seminars & Conferences – APAC, SIMC, etc.

• Student Development Programmes

• Student Convention

• BAJA SAE

• Formula SAE

• AeroDesign

• The society has over 100,000 registered members across the globe. It operates globally through its national chapters and affiliations with other bodies such as FISITA, etc.

• The Indian chapter contributes maximum number of members – 25000 registered members

Page 24: Team Kashpiers "Baja 2013"

INDUSTRIAL AFFILIATION OF BAJA

SAEINDIA

Dassault Systemes

Delphi

Mahindra & Mahindra

Mahindra Navistar

Maruti Suzuki

NATRIP

EASI

Eaton

EMITEC

ETAS

Precimaxtech

PTC

Sundaram Clayton

Toyota Kirloskar Motors

FIAT

Fleetguard

Force Motors

FORD

TVS Motors

UCAL Fuel

Varroc

Volvo India

ZF Steering

Ever since its inception, the event has been

well received by the industry. Some of the

associates of BAJA SAEINDIA include:

Anand Automotive Systems

Gabriel

GM India

HCL

Ansys

ARAI

Ashok Leyland

AVTEC

ICAT

ITW Chemin

JK Tyres

John Deere

Boeing

Bosch

Bharat Petroleum

Brakes India

Johnson Matthey

Liugong

Lombardini

Cumminsa

Page 25: Team Kashpiers "Baja 2013"

SAE INDIA BAJA

Baja is an inter-collegiate design

competition organized by the Society of

Automotive Engineering (SAE)

Provide Indian students with a

standard platform to showcase their

talent and potential not only in terms of

design and engineering, but also their

capability for team-work, entrepreneurial

skills and management.

The contest challenges each team to

function as a firm, whose task is to

design, fabricate, market and race-off an

off-road vehicle that will be evaluated on

a variety of manufacturing angles.

The vehicles are judged based on their

ability to maneuver and transverse harsh

off-road racing course while not

succumbing to the rigors of it.

Page 26: Team Kashpiers "Baja 2013"

TEAM KASHPIERS @ DSCE

» Started in May, 2010.

» With a mission of meeting the necessities and requirements of the industry by gaining practical knowledge and hands-on-experience.

» Amongst the Top-3 Collegiate Clubs in the Nation in terms of Members Strength, with 800+ members as of today.

» One of the most active Collegiate Clubs in the Country with atleast one event in a fortnight!

» Hosted a NATIONAL EVENT in just 14 months since formation.

» XXX, Princeton Review , Global Solution , Briggs and Stratton are few of our previous years’ sponsors.

Page 27: Team Kashpiers "Baja 2013"

STATUS UPDATE

10

59

68

84

39

ZONE WISE DISTRIBUTION

EAST

WEST

NORTH

SOUTH

CENTRAL

Page 28: Team Kashpiers "Baja 2013"

THE BAJA STORY

2009 2010 2011 2012 2013

54 75 80

100

130 106

146

198

250

300

BAJA MAIN EVENT

VIRTUAL BAJA

Page 29: Team Kashpiers "Baja 2013"

MEDIA PRESENCE

Page 30: Team Kashpiers "Baja 2013"

SPONSORSHIP BENIFITS

• The Company will gain ETHICAL value and provide moral support for the budding engineers of the future.

• Company name will be placed with Team name in all BROCHURE, college NEWSLETTER(Teckriti) , ANNUAL COLLEGE FESTS & AUTO EXPOS (Bangalore).

• BANNERS, PORSTERS, FLYERS of specific sizes will be displayed on campus

• The event is sponsored by various industrial giants like MAHINDRA , JK TYRE, ANSYS

• Print, Television, Radio media like DNA, DECCAN HERALD, TV 9 supporting the Team

• The company name will be published in the team WEBSITE.

• The company name will be displayed on the car at all times, bring it into the limelight.

• The competition will be witnessed over 5000’s of graduating engineers attracting them to the company

• The company will be displayed on the PARKING SLIP which will have a distribution rate of 600 per day.

The event will be witnessed by various GM, CEO & MD’s of the public and private sector companies.

Page 31: Team Kashpiers "Baja 2013"

FRONT VIEW SIDE VIEW

• The company will also feature on the helmets, Team T-shirts, Driver uniform,

Pit area, Bags, Business Cards & College Magazines

• The sponsoring company can use the college premises for advertisement and

publicity

SPONSORS’ SPACE

Page 32: Team Kashpiers "Baja 2013"

COST REPORT PARTICULAR Bill Amt in Rs Currently

1. VIRTUAL REGISTRATION 15,000/- Sponsored by college

2. BAJA REGISTRATION 35,000/- Sponsored by college

3. MATERIAL (CHROMOLY OR MILD STEEL 1024) 35,000/-

4. FORGING 3,000/-

5. TOOLS 25,000/-

6. FABRICATION 25,000/-

7. STEERING 5,500/-

8. SUSPENSION & ASSEMBLY 30,000/-

9. BRAKES 16,330/- Sponsored by TVS

10. TYRES 60,000/- Sponsored by CEAT

11. NUTS&BOLTS 3,000/-

12. FIBERGLASS 5,000/-

13. ELECTRICALS 4,000/- Sponsored by Minda

14. PAINT 5,000/-

15. TRANSMISSION

16. ENGINE (SERVICE)

17.TRANSPORT TO VENUE ( WITH INSURANCE)

18. TEAM TRAVEL AND ACCOMODATION

25,000/-

6000/-

25000/-

60000/-

TOTAL 3,82,300

Sponsored by B&S

Page 33: Team Kashpiers "Baja 2013"

ENGINE & DRIVE 35%

TRANSMISSION 11%

STEERING 2%

SUSPENSION 8%

FRAME & BODY 7%

BRAKES 6%

ELECTRICAL 2%

SAFETY 13%

MISCELLANEOUS 16%

MAJOR COST BREAKUP

GRAND TOTAL OF THE PROJECT : 3,82,300

…….

Page 34: Team Kashpiers "Baja 2013"

Monetary Assistance – Fund our project where we both benefit on the long run. Your company logo will be placed on various parts of the vehicle as well as on the driver’s apparel and helmet . PUBLICITY. Parts & accessories - Numerous parts are required in building the ATV like shockers , welding rods , frame /chassis metal , steering, speedometers, electrical systems, ignition systems and other components. Any material assistance is appreciated and the company logo will be placed on the vehicle. Benefits depends one the cost of the part/material. Technical Assistance – Our design team will require technical assistance frequently in order to solve real time problems . Your help will be greatly appreciated as technical sponsor and company logo will be advertised on the vehicle .Benefits depends on the level Assistance. Travel sponsors- our entire team will require to travel to various destinations across the country to compete and exhibit our vehicle .Also the cost of 20 people traveling for the competition. All Benefits will be provided to the sponsor. They will fall into the silver sponsor category. Transport sponsor- The team will require frequent delivery of parts for various places. A major portion of the cost will be incurred on transporting the car to the venue. This sponsor will fall into the Silver sponsor catogery

Media Sponsors – The entire team and the vehicle will have exclusive media coverage during the making as well as participation in the rally which will propagate your company’s presence as a sponsor .Social, Television, Radio, Print .

NOTE- Details on the size, location, Frequency of distribution of banner, posters, flyers, brochures, newsletters, advertisement spaces and social media publicity will be provided. Regular updates will be provided to all sponsors.

Page 35: Team Kashpiers "Baja 2013"

TITLE PLATINUM DIAMOND GOLD SILVER BRONZE

Name to be

placed before

team name * - - - - -

Flex Banners 8ft x 6ft 8ft x 4ft 6ft x 6ft 6ft x 4ft

4ft x 4ft 3ft x 2ft

Company Logo

in the PIT

LANE

FRONT

BACK

SIDE

SIDE

SIDE

WORKSH

OP

Part of

placement &

training

program * * * - - -

Hyperlink to all

associated

sites

FIRST

SECON

D

THIRD

FOURTH

FIFTH

SIXTH

Name of Co.

on the

brochure

FRONT

BACK

INSIDE

FRONT

BACK

INSIDE

FRONT

BACK

INSIDE

BACK

INSIDE

INSIDE

INSIDE

Logo on Team

Apparel * * * * * *

Page 36: Team Kashpiers "Baja 2013"

DESIGN

1-Suhas VR

2-Sagar M

3-Abhishek M

DESIGN

ELECTRICALS &

BRAKES

1-Apoorv B

2-Avijit P

POWERTRAI

N

1-Hansel P

2-Vinay SN

3-Dheeraj J

4-Huzefa P

5-Divyanshu P

MARKETING

1-Mohit M

2-Anurag S

3-Gaurav A

4-Siddhart P K

SUSPENSION

1-Varun J

2-Deepak K

STEERING

1-Pavan K

2-Girish P

Page 37: Team Kashpiers "Baja 2013"

THANK YOU

TEAM KASHPIERS