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Presentation by :
Gowri Shanker.K
Hariharan.B
Rahul Dharmarajan
Srinivasan E.R
RULEBOOK
SPECIFICATIONS
MAX VALUES
CRIMSON
THRUSTERS
1.
Length, Width
108, 64
80,62
2.
3.
SIM placement
10
4.
41
45
5.
6 to 28
10.5
6.
Fasteners
Metric 8.8
7.
Primary: 0.120
Secondary: 0.035
0.12
8.
Primary: 1
Secondary: 1
9.
10.
420kg
11.
Wheel base
58
12.
Maximum speed
60kmph
54.5kmph
13.
Ground Clearance
12.5
14
Tyre dimensions
25x8x12
Market Survey
Data Assumption
Design
Calculation
OEM Comprison
& Selection
Virtual Design
FEA
Completion
Roll Cage
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 4130
Yield strength
:600 N/mm2
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 56
Maximum number of welds at a point is 2
Roll Cage
TEST
DETAILS
RESULTS
Max Stress(N/mm2)
224.332
FRONT
Load Applied(N)
20,000
IMPACT
TEST
Max Deflection(mm) 1.50883
FOS
2.7
Max Stress(N/mm2)
296.421
REAR
Load Applied(N)
20,000
IMPACT
TEST
Max Deflection(mm) 1.359
FOS
2.1
Max Stress(N/mm2)
284.399
SIDE
Load Applied(N)
13,000
IMPACT
TEST
Max Deflection(mm) 4.967
FOS
2.2
STRESS ANALYSIS
DISPLACEMENT
Roll Cage
TEST
ROLL
TEST
BUMP
TEST
DETAILS
RESULTS
Max
Stress(N/mm2)
328.304
Load Applied(N)
9,000
Max
Deflection(mm)
15.2842
FOS
Max
Stress(N/mm2)
313.525
Load Applied(N)
5,000
Max
Deflection(mm)
12.2493
FOS
STRESS ANALYSIS
DISPLACEMENT
Parameter
Crimson
Thrusters
Maruti 800
37o
37o
26o
32o
Steering ratio
15 : 1
17 :1
Turning radius
3.133 m
4.4 m
Steering Geometry
Caster
7o
Disc Brake
Camber
1o
4:1
4:1
37o
19.05
22.25mm
19.05mm
26o
42mm
43mm
42mm
Turning Radius
3.133m
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
Parameters
Target
Santro
Omni
Type of Brake
Disc Brake
Disc Brake
Pedal Ratio
4:1
Diameter of Master
Cylinder
Parameters
Front suspension
Rear suspension
Type
Wire diameter
9mm
57 mm
Number of coils
11
Total length
322.63mm
540 mm
231.71mm
58.55mm
208.8396mm
13.281o
1.413o
Caster angle
7o
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
9mm
12 mm
97 mm
Drive Train
The power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way
Gear
Final
Gear
Ratio
Max
Tractive
Effort
(N)
2119.32
Final
Gear
Ratio
31.48
Max
Vehicle
Speed
(Kmph)
12.7
55.08
Max
Vehicle
Speed
(Kmph)
7.27
Max
Tractive
Effort
(N)
3708.14
First Gear
Second
Gear
Third Gear
18.70
21.4
1258.94
32.72
12.23
2202.80
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
Reverse
Gear
55.08
7.27
3708.14
31.48
12.71
2119.32
Engine
Gearbox
Drive shaft
Stub axle
Engine working range (M) = 1750rpm3800rpm
Recommended maximum power (PM) = 6.7
KW 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
Wheels
Electrical Circuit
VALUES
Visibility
67
61.59
20
79.48
53
Design Aspect
Roll Cage
Criteria
SAE BAJA Rule Book Section 3
Roll over
Result
Achieved
Below yield stress
Below yield stress
Below yield stress
Below yield stress
Suspension
Achieved
Steering
Achieved
Achieved
Achieved
Brakes
Transmission
Electricals
Achieved
INNOVATIONS:
Fly ash incorporation in brakes
Piezo Electric power generation
Roll cage diameter optimization
Component
(X,Y,Z Coordinates)
Weight (kg)
Engine
(339,316,-1230)
30
Gearbox
(247,307,-851)
15
Seat
(671,566,-1050)
Driver
(973,529,-1100)
80
Steering
(1550,502,-1050)
(314.6,163,-162)
1.265
(311,163,-1950)
1.265
(1780,165,-296)
1.265
(1780,165,-181)
1.265
(314.6,158,-112)
20.246
(315,158,-1960)
20.246
(1780,158,-286)
20.246
(1780,158,-1820)
20.246
(306,367,-430)
1.2985
(306,367,-1600)
1.2985
(1790,337,-585)
.5234
(1790,337,-1520)
.5234
Brake Pedal
(1730,132,-1090)
.586
Clutch Pedal
(1730,132,-981)
.586
Acceleration Pedal
(173,132,-878)
.586
Name
Role in Team
Aravindh
Machinist / Brake
Adithyan
Design / Administration
Harish
Inspection / Machinist
Harikrishnan
Co-Driver / machinist
Arun
Electrician
Benraja
Design
Madumitha
Machinist / Steering
Design / Welding
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