L/O/G/O

www.themegallery.com

ROADIES

National Institute of Foundry & Forge

Technology , Ranchi

Design Presentation

Regd. ID : 81341

TEAM CAPTAIN

TEAM VICE-CAPTAIN

TECHNICAL

Design &

Analysis

Roll Cage Steering Suspensions Tires &

Brakes

Fabrication

MANAGEMENT

Publicity Sponsorship Procurement

RICHARD DOLEY AKSHAY TRIPATHI

VIKAS UTSAV

KR. SAMBHAV UTSAV MAHTO

ANUROOP, RAJA,SATISH

DHARMENDRA RAJAT

BITTU GUPTA ROHIT UJJIR

MANAS GOND HITESH GODWANI

CHAITANYA DWIVEDI VISHAL PANDEY

ABHIMANYU

RAJ VARDHAN ANKIT GUPTA

ASHUTOSH

RISHIKANT

TEAM ORGANIZATION

ROLL CAGE Material Carbon Steel AISI 1018

UTS 365 Mpa

Carbon content 0.18%

Outside dia.:

Wall thickness:

25.4 mm

3.05 mm

DESIGN METHODOLOGY

WELD JOINTS

• Driver-oriented Cockpit design. • Light weight, Compact and simple.

• High Roll stiffness and structural rigidity

• Easy egress during mishap.

• Least no. of welds and members

Number of weld joints

Weld length

= 62 = 4.787 m

Roll Cage Analysis (Software: ANSYS 13.0)

Front Impact Analysis At Speed : 60 km/hr (16.67 m/s)

Impact Time : 0.1 sec

Thus, Load= 60000 N on front members.

Max STRESS : 174 Mpa

Max DISPLACEMENT : 2.38 mm

Factor of Safety: UTS/Smax = 365/174

= 2.1

Side Impact (Safe case of Side Roll over) Load: 2G loading (6180 N) on side members.

Max STRESS : 69.4 Mpa

Max DISPLACEMENT : 2.26 mm

Factor of Safety : 365/69.4

= 5.25

Roll Over (Dynamic) Analysis Load: 2G Horizontal on side members

1G Vertical on top members.

Max STRESS :136 Mpa

Max DISPLACEMENT : 5.5 mm

Factor of Safety : 2.68

Suspension: Double Wishbone Parallel SLA

Upper arm 312 mm

Lower arm 338 mm

Upper arm 263 mm

Lower arm 287 mm

Front Lower arm , centre

Rear Upper arm, inner

SHOCK MOUNTING

LOCATION:

LENGTH OF A ARMS:

Front

Rear

REAR UPPER ARM

FRONT LOWER ARM

Front 81.66 mm

Rear 114.82 mm

ROLL CENTER HEIGHT:

Steering

Gear Ratio 12:1

Caster 5° Positive

Camber (static) 2° Negative

Toe-in 10 mm

King-pin Inclination 12°

Scrub Radius 44 mm

Lock Angle 40° (approximately)

No. of turns to steer from Extreme Left

to Extreme Right

2.66 turns

Turning Radius

Target Specifications:

• Rack and Pinion; simple design and easy to install.

•100% Ackermann geometry

Braking System

Pedal Ratio 6.2:1

Braking Effort 1300 N per wheel

Deceleration 7.53 m/s2

Stopping distance 21.5m (max speed 60 km/h)

Assumption: Brake Efficiency = 70%

Coefficient of friction =0.65

Formula used ῖ = BfwR/r Bf = Mag s = v2/ 2gaₓ/g

Maruti 800 calipers and disc will be used

Target Specs:

Features:

Hydraulic disc brakes

Two independent braking circuit

Equipped with SMART Turning Assistance System

Two servo motor assisted valves on rear circuit.

While turning left, on application of brakes will lock both the

front wheels and rear left wheel.

Rear right wheel with drive will get moment along these 3 locked

wheel hence turning would be easier.

Power Train

Torque* (ft-lbs,

gross) 14.50

Engine

Displacement (cc) 305

Number of

Cylinders Single

Engine

Configuration Horizontal Shaft

Engine

Technology OHV

Length (in) 12.3

Width (in) 15.4

Height (in) 16.4

Weight (lbs) 50.4

Bore (in) 3.12

Stroke (in) 2.44

Engine Fuel Gasoline

SPARK PLUG RC12YC

Briggs and Stratton Engine:

10 hp OHV Intake

20S332 0036 New engine

with 3800rpm

Overhead Valve Design (OHV)

Runs cooler and cleaner delivering

more power, longer engine life and

improved fuel economy

Flange Coupling

Safety & Ergonomics Kill switches will be installed

to kill the ignition in case of

emergency

All rotating parts will be

properly shielded with sheet

metal. Splash shields and Drip

pans will also be provided

5 point harness seat

belt system along with

neck restraint and arm

restraint

Belly pan running entire

length of cockpit, Roll

cage foam padding and

body panels will be

provided

Fire extinguisher within

the reach of driver will

be provided

SAE grade brake lights

will be installed and all

wiring will be properly

insulated and clipped.

Pivoted bumper with spring

support in front

of vehicle to absorb energy

from collisions

Racing type 3 ways

Adjustable seats, for

driver comfort.

Belly pan and Roll

cage padding

Gear indicator to

enable quick gear

shifts

Design Specifications

Overall length 2.3 m

Track width Front: 1.55 m

Rear: 1.45 m

Wheel base 1.60 m

Overall weight 310 Kgs (inclusive of Driver)

Engine Briggs and Stratton 10hp OHV

Transmission Mahindra Alfa(modified)

Tires

Rims

22 x 8 inches, 6 ply ATV

10 x 6 inches

Roll Cage SAE 1018 seamless steel tubes

1” OD and 3 mm wall thickness

Suspension (front and rear) Double Wishbone suspension

(Parallel and unequal arms)

Steering System Customized Centered Rack and Pinion

Gear Ratio = 12:1

Braking (front and rear) Hydraulic Disc brakes

Maximum Torque 19 Nm @ 2900 rpm

Maximum Speed 60 KMPH

2-D views

Final View

Design Validation Plan

No Description Accomplishment

Targets

Allotted

Resource

Means Of Accomplishment

1. Welding test Strength of welded

components should be within

permissible limits.

Abhimanyu

Yadav

Universal Testing machine

2. Ground Clearance

Test

Should not be less than the

specified value i.e. 10 inch

Ashutosh

Saraswat

10 inch Spacer.

3. Braking Test The vehicle should stop within

safe limits and all the wheels

should be locked

Ankit Gupta To be tested on track with 2 different observers

for wheels on each side. Braking distance to be

measured from point of brake application to

point of stop.

4 Wheel Travel Should be at least 6-7 inches

(jounce rebound)

Raja Sah Ruler

5. Straight Line Stability Should move in a straight line

when steering is at neutral

position.

Rohit Ujjir Driving the car in neutral steering position

parallel to the white strips on road.

6. Turning Radius Should be approximately

equal to the calculated value.

Anuroop

Kulshresta

Radius will be measured using measuring tape.

7. Fuel Leak Test Should not leak fuel or fluid at

any circumstances.

Vishal Pandey Vehicle should be tested in various roads

conditions and any case of spills to be

scrutinsed.

8. Speed and

acceleration test

By recording the time travel

while traversing a path

Hitesh Godwani Obtained data shall confirm the calculated

value

College & External Facilities MACHINING Center Lathe Universal Milling Machine Grinding Machine Drilling Machine WELDING

Metal Inert Gas welding machine TIG welding machine Electric arc welding machine

MANUFACTURING MACHINES

CNC Milling Machine

Hot Isostatic Press(HIP) Machine

Rapid Prototyping Machine

TESTING MACHINES

Brinell Hardness testing machine(3000 kg)

Universal tensile testing machine(60 tonne)

EXTERNAL FACILITIES:

CNC Pipe Bending.

Laser Cutting (for hubs).

Paint Equipment.

Project Plan

Cost Estimates

Category Items Cost

Frame Steel tubes, Sheet Metal,

Welding supplies, roll cage

padding etc

37,200

Power Train Engine, transmission, shifters,

chains, sprocket, couplings etc 47,000

Wheels and tires Rims & tires(4+2) 39,900

Suspension Shocks, springs, A arms, uprights,

hubs, spindles 22,000

Steering Rack & pinion, steering column,

steering arm, steering wheel, tie

rods etc

11,600

Safety equipments Driver’s suit, helmet, fire

extinguisher, harness system,

restraints, kill switch etc

37,500

Braking Calipers, master cylinders, servo

motors, brake lines etc 14,500

Misc Travel, transportation,

accommodation etc 30,000

Total 2,39,700

THANK YOU!!!