4 GKDC

TH
design your dreams
• Major changes in rulebook
• Challenges in the event
• Stages involved
• What is PFR
• PFR Presentation

What is GKDC
30min
• What is Gantt Chart
• What is the importance of this report
• How should one proceed to make a proper Gantt Chart
• Factors to be considered while making Gantt Chart
• Importance of timeline in Gantt Chart
• Sample format

Gantt Chart
25min
• What is DVP
• Importance of DVP
• Tests to be included in DVP
• Understanding the procedure
• Duty allocation
• Testing Reports
• Deadlines in DVP
• Understanding the Format

DVP
25min
• What is FMEA
• Importance of FMEA
• Failures to be included in FMEA
• Understanding the procedure
• What is Failure Mode
• What is Potential Cause of Failure mode
• What is Detection
• What is Severity
• What is RPN
• What are Rating Factors
• Understanding the Format

FMEA
45min
• What is Cost Report
• Cost factors involved
• Cost of components
• Material Cost
• Process Cost
• Fasteners Cost
• Tooling
• Labor Cost
• Miscellaneous
• Need of Pie Chart/Graph

Cost Report
30min
• Business Idea
• Type of Business
• Mission, Vision
• Company Hierarchy
• Target market/audience and their expectations
• Initial Investment
• Investors Scope
• Investment Proposals
• Investment Policies
• Production Plans
• Infrastructure Required
• Labor/Employee Management
• Machinery Required
• Turnover & Figures Justification
• Break Even Analysis
• Confidentiality Clause

Business Plan
60min
• Acknowledgement
• Table of Contents
• Abstract
• Introduction
• Goal of Project
• Technical Specifications
• Special Features
• Chassis
• Chassis Analysis
• Engine & Transmission
• Braking
• Steering
• Wheel & Tyres
• Body Works
• References

Design Report
Acknowledgement
10min
• Table of Contents
• Table of Figures
• Table of Signs/Notations

Table of Contents
10min
• Small description of Design Report

Abstract
10min
• Introduction to the Design Challenge
• Introduction to the Organization conducting it
• Introduction to the team and its aim

Introduction
10min
• Rulebook Satisfaction
• Aesthetics Expectations
• Ergonomics Expectations
• Safety
• Light Weight
• Performance Expectations

Goal of Project
20min
Overall length 67 inches

Overall width 49.5 inches

Wheelbase 44.5 inches

Track width Front: 43 inches Rear: 36.5 inches

Ground Clearance 1.75 inches

Centre of Gravity X, Y, Z Coordinates

Overall weight 130 kg (including driver)

Engine Honda Shine 125cc

Drivetrain CVT

Tyres FRONT 10x4.50x5 inches , REAR 11x7.10x5

inch
Braking Hydraulic disc Brake–200 mm Diameter,
Stopping Distance (40km/hr) : 11m (1.9 sec)
Steering Turning Radius : 1.48m Camber : +2 ̊

Acceleration 9 m/sec2

Technical Specifications
10min
Special Features
10min
• Rulebook Requirements
• Design Considerations
• Performance Expectations
• Material Selection and Reasoning
• Material Calculation
• Material Certification
• Chassis Design Goals
• Methodologies
• Design VS Manufacturability

Chassis
30min
• Calculation of Impact Forces
• Fixed Geometry/Constraints
• Direction of Forces
• Force in terms of g’s
• Frontal Impact
• Side Impact
• Rear Impact
• Factor of Safety

Chassis Analysis
60min
• Rulebook Constraints
• Specifications of Engine
• Gear Ratio
• Final Drive Ratio
• Acceleration Calculations
• Power Limited Acceleration
• Traction Limited Acceleration
• Maximum Speed

Engine & Transmission

60min
• The analysis of power limited acceleration involves
examination of the engine characteristics and their
interaction through the power train
• The ratio of engine power to vehicle weight is the first
order determinant of acceleration performance
• At low moderate speeds an upper limit on the
acceleration can be obtained by neglecting all resistance
forces acting on the vehicle

Power Limited Acceleration

• Power and Torque are related by speed. Specifically,
• HP = T (ft-lb) x ωe(rad/sec)/550
• Also
• Power (KW) = 0.746 x HP

• From Newton’s Second Law –

• Fx = M ax
•
• Where
• M = Mass of Vehicle (w/g)
• ax = Acceleration in forward direction
• Fx = Tractive force at drive wheels
•
• ax = Fx/M = 550 (g x HP)/(V x W) (ft/sec2)

Power Limited Acceleration

• Presuming there is adequate power from the engine, the
acceleration may be limited by coefficient of friction
between tyre and road,
Fx = μW

Traction Limited Acceleration

• Ground Clearance
• Front Tyres
• Rear Tyres
• Wheel Assembly
• Components Design & Analysis

Wheels & Tyres

25min
• Rulebook Requirements
• Brake Test Procedure
• Basic Equation of Brakes
• Constant Deceleration
• Braking Forces
• Stopping Distance and Stopping Time
• Brake test qualifying criterion

Braking
60min
• From Newton’s Second Law

Where,
W = Vehicle Weight
g = Gravitational Acceleration
Dx = - ax = Linear Deceleration

Basic Equation of Brakes

• We can write linear deceleration as –
Where,
Fxt = total of all longitudinal deceleration forces on the
vehicle
V = Forward velocity

This equation can be further integrated V0 to Vf

Constant Deceleration
• V0 – Vf = (Fxt/M) ts
Where,
Ts = time for the velocity change
Because velocity and distance are related by V = dx/dt, we can
substitute for dt in equation -

Constant Deceleration
• ½(V02 – Vf2) = (Fxt/M) X

Where,
X = Distance travelled during deceleration

Constant Deceleration
• In case where deceleration is a full stop, then Vf is zero
and X is the stopping distance SD, then;

Constant Deceleration
• And time to stop is -

Constant Deceleration
• Rolling Resistance
• Aerodynamic drag
• Driveline Drag
• Grade
• Brakes
• Tyre-Road Friction
• Inflation Pressure
• Vertical Load

Braking Forces
• Rulebook Requirements
• Go Kart Steering System
• Design
• Ackerman’s Geometry

Steering
25min
• Rulebook Requirements
• Aesthetics
• Material for Bodyworks
• Weight Factor

Body Works
30min
• CoG
• Static Load Distribution
• Design Symmetry
• Lateral Load Transfer
• Longitudinal Load Transfer
• Chassis Stiffness
• Increasing Torsional Stiffness
• Bending Stiffness
• Effects of Banking (Advanced)
• Asymmetrical Effects

Other Important Discussions

CG Loacation
60min
Static Load Distribution
25min
Design Symmetry
10min
Lateral Load Transfer
40min
Longitudinal Load Transfer
20min
Chassis Stiffness
15min
Increasing Torsional Stiffness
15min
Bending Stiffness
15min
Asymmetrical Effects
20min
• Coordination of Team Members
• Lengthy Presentation
• Time Factor
• Lack of Knowledge of the Content included in PPt
• Nervousness
• Fear of Disqualification
• Bad interview/viva
• Lack of Presentation Skills

Problems Encountered in PFR

30min