virtuals report

8/12/2019 virtuals report

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CRIMSON THRUSTERSTeam ID: 14042

Anand Institute of Higher Technology

Presentation by : Gowri Shanker.K Hariharan.B Rahul Dharmarajan Srinivasan E.R


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All the members of the roll cage are made of SAE 4130 steel with OD 1 and wall thickness of .118(3mm).

PROPERTIES OF MATERIAL:Material :SAE 4130Yield strength :600 N/mm 2 Carbon composition :0.3%C(>0.18%C)The total weight of the roll cage is estimated to be 62kg.

Total number of weld joints is 56Maximum number of welds at a point is 2

The driver ergonomics for roll cageElbows to side impact member= 3.5 Drivers seat to fire wall(RRH)= 3 Drivers head to front bracing member= 15Drivers helmet to top of the vehicle= 7

Overall roll cage length = 80Wheel base = 59Overall roll cage width = 42

Overall roll cage height = 54 Overall width = 58

Roll Cage


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Roll CageTEST DETAILS RESULTS STRESS ANALYSIS DISPLACEMENT

FRONTIMPACT

TEST

Max Stress(N/mm 2) 224.332

Load Applied(N) 20,000Max Deflection(mm) 1.50883

FOS 2.7

REARIMPACT

TEST

Max Stress(N/mm 2) 296.421

Load Applied(N) 20,000

Max Deflection(mm) 1.359

FOS 2.1

SIDEIMPACT

TEST

Max Stress(N/mm2

) 284.399Load Applied(N) 13,000

Max Deflection(mm) 4.967

FOS 2.2


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TEST DETAILS RESULTS STRESS ANALYSIS DISPLACEMENT

ROLLTEST

MaxStress(N/mm 2)

328.304


MaxDeflection(mm) 15.2842

FOS 2

BUMPTEST

MaxStress(N/mm 2)

313.525


MaxDeflection(mm)

12.2493

FOS 2

Roll Cage


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Parameter Crimson

Thrusters

Maruti 800

i 37o 37o

o 26o 32o

Steering ratio 15 : 1 17 :1

Turning radius 3.133 m 4.4 m

100 % Ackermanns steering Proposed track width = 54 Proposed wheel base = 58

Steering set up Adams car

Type of steering :Rack and pinion

Maximum Angular travelof steering wheel : 540 o

Tie rod length = 9.889 Steering effort = 20 N

Scrub radius Vs Steering angle


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Brake System

Parameters Target Santro Omni

Type of Brake Disc Brake Disc Brake Disc BrakePedal Ratio 4:1 4 : 1 4 : 1

Diameter of MasterCylinder

19.05 22.25mm 19.05mm

Caliper Piston EffectiveDiameter

42mm 43mm 42mm

Rotor Effective Diameter 230mm 230mm 230mm

Braking Force 3296.16 N 3257.399 N 4239.38 N

Stopping Distance 14.33m 14.5 m 11.145 m

Deceleration 0.8g 0.925g 1.028g

OEM Selected: Maruthi OMNIs Braking System Weight Transferred: 208.43NDynamic load acting on front during braking: 2848.45 NDynamic load acting on rear during braking: 1271.74 N

Brakes and SteeringSteering Geometry

Caster 7 o

Camber 1o

Steering angle inner wheel 37 o

Steering angle outer wheel 26 o

Turning Radius 3.133m


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Parameters Front suspension Rear suspension

Type Unequal , parallel double wishbone

Mac Pherson Strut

Wire diameter 9mm 9mm 12 mm

Mean coil diameter 57 mm 97 mm

Number of coils 11 5 4

Total length 322.63mm 540 mm

Lower wishbone or control armlength 231.71mm 58.55mm

Upper wishbone length 208.8396mm -

Inclination of wishbone wrtground

13.281o 1.413o

Caster angle 7 o 0o

Camber +1o +1o

Scrub radius 5mm 5 mm

Spring stiffness 9 N/mm 9.8 N/mm

Motion ratio 2.4 2.61

Spring travel 62.5 mm 57.4 mm


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Camber Vs wheel travel

Scrub radius Vs wheel travelToe angle Vs wheel travel


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Drive TrainThe power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way

Gear Final

GearRatio

Max

VehicleSpeed(Kmph)

Max

TractiveEffort(N)

Final

GearRatio

Max

VehicleSpeed(Kmph)

Max

TractiveEffort(N)

First Gear 31.48 12.7 2119.32 55.08 7.27 3708.14

SecondGear

18.70 21.4 1258.94 32.72 12.23 2202.80

Third Gear 11.40 35.11 767.48 19.95 20.06 1343.09

Fourth Gear 7.35 54.45 494.82 13.40 29.87 902.13

ReverseGear

55.08 7.27 3708.14 31.48 12.71 2119.32

Engine

Gearbox

Drive shaft

Stub axle

Wheels

Engine working range ( M ) = 1750rpm-3800rpm Recommended maximum power (PM) = 6.7KW at 3800rpm To calculate power performance function Pe = P1 e + P2 e2 - P3 e3 P1 = PM/ M P1 = 16.8455 /s P2 = PM/ M2 P2 = .04235 /s P3 = PM/ M3 P3 = 1.064 E -4 /s Therefor power performance function is Pe = 1608455 e + 0.04235 e2 1.064 E-4

e3


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Electrical Circuit


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Ergonomics and ValidationERGONOMICPARAMETER

VALUES

Visibility 67

Front visibility distance 61.59

Seat rest angle 20

Cock pit length 79.48

Cock pit height 53 Design Aspect Criteria Plan and Analysis Methodology Result Roll Cage SAE BAJA Rule Book Section 3 FEA :

Front Impact TestSide Impact TestRear Impact TestRoll over

AchievedBelow yield stressBelow yield stressBelow yield stressBelow yield stress

Suspension To provide good cushioning against shocks, withoutfailure.

1. ADAMS shall be used to determine the performanceof the suspension.2. Load will be applied on the vehicle in dynamic andstatic conditions to test the performance of thesuspension.

Achieved

Steering To design a steering mechanism which satisfies Ackermanns mechanism and also provide self centeringeffect and avoids nervousness.

The system that gives the required turning radius andthe least steering effect will be selected.

Achieved

Brakes To design a braking system which provides comfortablestop at a distance of 14.3m

The system that gives stopping distance closest to 11.14m and best suitable will be selected.

Achieved

Transmission To increase the torque and speed of the vehicle to meetthe demands of the hill climbing test.

To select the required gear ratio, which gives torque andspeed.

Achieved

Electricals To provide fool proof lighting and sound circuits To design the kill switch and the various circuitry Achieved


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Component (X,Y,Z Coordinates) Weight (kg)

Engine (339,316,-1230) 30

Gearbox (247,307,-851) 15

Seat (671,566,-1050) 2

Driver (973,529,-1100) 80

Steering (1550,502,-1050) 6

Back Right Brake (314.6,163,-162) 1.265

Back Left Brake (311,163,-1950) 1.265

Front Right Brake (1780,165,-296) 1.265

Front Left Brake (1780,165,-181) 1.265

Back Right Tyre (314.6,158,-112) 20.246

Back Left Tyre (315,158,-1960) 20.246

Front Right Tyre (1780,158,-286) 20.246

Front Left tyre (1780,158,-1820) 20.246

Front Right Suspension (306,367,-430) 1.2985

Front Left Suspension (306,367,-1600) 1.2985

Back Right Suspension (1790,337,-585) .5234

Back Left Suspension (1790,337,-1520) .5234

Brake Pedal (1730,132,-1090) .586

Clutch Pedal (1730,132,-981) .586

Acceleration Pedal (173,132,-878) .586

The centre of gravity for the entire vehicle is located at(995,189,-1050) which is below the seat

Co-Ordinates and Innovations

INNOVATIONS : Fly ash incorporation in brakes Piezo Electric power generation Roll cage diameter optimization


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Team Faculty Advisor : DhanasekharTeam Captain : Mohammed Zaid

S.No Name Role in Team

1 Aravindh Machinist / Brake

2 Adithyan Design / Administration

3 Harish Inspection / Machinist

4 Harikrishnan Co-Driver / machinist

5 Arun Electrician

6 Benraja Design

7 Madumitha Machinist / Steering

8 Sahithya Sabari Gireesh Design / Welding

9 Pawan Kumar Inspection / Machinist

10 Sai Vishnu Machinist / Administration

11 Gowri Shanker Design / Welding

12 Dhivaker Machinist / Driver

13 Mohammed Zaid Stocker / Machinist

14 Manikandan Inspection / machinist

15 Mahendran Machinist

16 Mohammed Mudassir Machinist / Stocker

17 Hariharan Machinist / Stocker

18 Manoj Somoosay Machinist / Steering

19 Varun Inspection / Stocker

20 Vaisikan Electrician

21 Rahul Dharmarajan Design / suspension

22 Vaishnavi Machinist / Suspension

23 Srinivasan Machinist / Steering

24 Soorya Machinist / Brakes

25 Deepak Welding


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Documents

virtuals report