17068_Team SAMKARAN_CAD/CAE Report

Author’s Name: Co-Author’s Name:

1. INTRODUCTION =(365 × 106)×(10136.74 × 10-12) ÷ (12.7 × 10-3

= 291.33 Nm
{First of all, read the instructions given at the end of this
document carefully. a) AISI 1018 (28 x 1.6 mm)
E = 205 GPa
Under this section introduce the approach of starting I = [π×(28)4 ÷64] - [π×(24.8)4 ÷64]
your CAD Model. If any hand sketches were made, =11603.36 × 10-12 m4
these can be provided at the end of report. If any
prototype was made then photographs must be Bending Stiffness = E×I
incorporated. Introduce the software used for CAD & =205×109 × 11603.36 ×10-12
CAE work with their full name and versions. Please try =2378.68 Nm2
to limit the introduction to 100 words.}
Bending Strength = (Y×I)÷d
2. FRAME MATERIAL OPTIONS d= distance from neutral axis to extreme fibre
=(365 × 106)×(11603.36 × 10-12) ÷ (14 × 10-3 ) =
i. Steel (AISI 1018) 302.51 Nm
Circular cross section; 28 x 1.6 mm
b) AISI 4130 (28 x 1.6 mm)
ii. Steel (AISI 4130) E = 205 GPa
Circular cross section; 28 x 1.6 mm I = [π×(28)4 ÷64] - [π×(24.8)4 ÷64]
=11603.36 × 10-12 m4

Bending Stiffness = E×I

=205×109 × 11603.36 ×10-12
Material Y U W C t
=2378.68 Nm2
AISI 1018 365 440 290 7
Bending Strength = (Y×I)÷d
(28x1.6mm
d= distance from neutral axis to extreme fibre
)
=(460 × 106)×(11603.36 × 10-12) ÷ (14 × 10-3 )
= 381.25 Nm
AISI 4130 460 560 520 7
(28x1.6mm
Property Reference Optional Material
)
/Material Material Material Used
Y: Yield Strength (MPa) AISI 1018 AISI 4130 AISI 1018
(25.4 x 2 (28 x 1.6 (28 x 1.6
U: Ultimate Strength (MPa) mm) mm) mm)
W: Total Chassis Weight (kg) Bending 2078.03 2378.68 2378.68
Stiffness Nm2 Nm2 Nm2
C: Cost (₹/m)
Bending 291.33 Nm 381.25 Nm 302.51 Nm
t: Time of Delivery (days) Strength
3. CALCULATION OF BENDING STRENGTH
AND BENDING STIFFNESS
4. CAE ANALYSIS OF VEHICLE/FRAME
AISI 1018 (25.4 x 2 mm)
E = 205 GPa This CAE analysis shall be formed on all materials
I = [π×(25.4)4 ÷64] - [π×(21.4)4 ÷64] considered as frame material option as mentioned in
=10136.74 × 10-12 m4 Sr. No. 2 above.}
Bending
Stiffness = E×I =205×109 ×
4.1. FRONTAL IMPACT ANALYSIS
10136.74×10-12 =2078.03 Nm2

Bending Strength = (Y×I)÷d Steel (AISI 1018, 28x1.6mm)

d= distance from neutral axis to extreme fibre
a) Assumption & Considerations:

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  The properties of the material are: F = m*a; a = v/t;

Yield Strength - 365 MPa Where

Modulus of Elasticity-205 GPa m=mass, a=acceleration, v=velocity,

Poisson’s ratio- 0.29 t=time, F=force

Density- 7870 kg/m3 m=230 kg; v=11.11 m/s; t= 0.2 s;

ii. AISI 4130 a=11.11/0.2 = 55.55 m/s2

Yield Strength - 460 MPa F= 230 x 55.55 = 12776.5 N

Modulus of Elasticity-205 GPa c) Analysis Results:

Poisson’s ratio- 0.29 Maximum Deformation = 2.3mm

Density- 7850 kg/m3 The CAE model is as follows:

 The components omitted before conducting

analysis on the design are:

Pedal mounts, Seating mounts, Rear wheel

mount and Payload mount.

 The following assumptions have been made

regarding the impact condition:

1) The total mass of the vehicle is 230 kg.

Maximum Tensile Stress = 1.33 N/mm2
2) A vehicle travelling at 11.11 m/s (40 km/hr)
rams into a stationary mass longitudinally. Factor Of Safety = 2.78
3) The crash impulse time is 0.2s. The CAE model is as follows:
 Boundary Conditions:

The rear wheel suspension points in all

directions and front wheel suspension points in
Y direction are constrained.

d) Optimizations:

Any optimizations performed on the vehicle/ frame

should be listed down here.

Similarly, show the frontal impact analysis of

vehicle/frame with other material options.

4.2. SIDE IMPACT ANALYSIS

Steel (AISI 1018, 28x1.6 mm)

 Meshing element size: 3mm
a) Assumption & Considerations:
b) Calculation of Impact Forces:
 The properties of the material are:
Formulae:

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 Yield Strength - 365 MPa t=time, F=force

Modulus of Elasticity - 205 GPa m=230 kg; v=11.11 m/s; t= 0.3 s;

Poisson’s ratio - 0.29 a = 11.11/0.3 = 37.03 m/s2

Density - 7870 kg/m3 F = 230 x 37.03 = 8516.9 N

ii. AISI 4130

c) Analysis Results:
Yield Strength - 460 MPa
Maximum Deformation = 4.2 mm
Modulus of Elasticity-205 GPa
The CAE model is as follows:
Poisson’s ratio- 0.29

Density- 7850 kg/m3

 The components omitted before conducting

analysis on the design are:

Pedal mounts, Seating mounts, Rear wheel

mount and Payload mount.

 The following assumptions have been made

Maximum Tensile Stress = 2.53 N/mm2
regarding the impact condition:
Factor Of Safety = 1.46
1) The total mass of the vehicle is 230 kg.
The CAE model is as follows:
2) A vehicle of mass 230 kg travelling at 11.11
m/s (40 km/hr) rams to the vehicle laterally.

3) The crash impulse time is 0.3s.

 Boundary Conditions:

The suspension points of front and rear wheel

towards the right are constrained.

d) Optimizations:

Same as given in 4.1..

Similarly, show the side impact analysis of

vehicle/frame with other material options.

4.3. ROLLOVER ANALYSIS

Steel (AISI 1018, 28x1.6 mm)

 Meshing element size: 3mm a) Assumption & Considerations:

b) Calculation of Impact Forces:  The properties of the material are:

Formulae: Yield Strength - 365 MPa

F = m*a; a = v/t; Modulus of Elasticity - 205 GPa

Where Poisson’s ratio - 0.29

m=mass, a=acceleration, v=velocity, Density - 7870 kg/m3

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 Maximum Deformation = 2.99 mm
ii. AISI 4130
The CAE model is as follows:
Yield Strength - 460 MPa

Modulus of Elasticity-205 GPa

Poisson’s ratio- 0.29

Density- 7850 kg/m3

 The components omitted before conducting

analysis on the design are:
Maximum Tensile Stress = 2.15 N/mm2
Pedal mounts, Seating mounts, Rear wheel
mount and Payload mount. Factor Of Safety = 1.72
 The following assumptions have been made The CAE model is as follows:
regarding the impact condition:

1) The total mass of the vehicle is 230 kg.

2) Impact load considered is of 3g magnitude.

 Boundary Conditions:

The suspension points of front and rear wheels

are constrained.

d) Optimizations:

Same as given in 4.1..

Similarly, show the rollover analysis of vehicle/frame

with other material options.

4.4. REAR IMPACT ANALYSIS

Steel (AISI 1018, 28x1.6mm)

a) Assumption & Considerations:

 Meshing element size: 3mm
 The properties of the material are:
b) Calculation of Impact Forces:
Yield Strength - 365 MPa
Formula:
Modulus of Elasticity-205 GPa
F = m*a;
Poisson’s ratio- 0.29
Where
Density- 7870 kg/m3
m=mass, a=acceleration, F=force
ii. AISI 4130
m = 230 kg;
Yield Strength - 460 MPa
a = 3g
Modulus of Elasticity - 205 GPa
F= 230*3*9.81 = 6768.9 N
Poisson’s ratio - 0.29

c) Analysis Results: Density - 7850 kg/m3

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  The components omitted before conducting
analysis on the design are:

Pedal mounts, Seating mounts, Rear wheel

mount and Payload mount.

 The following assumptions have been made

regarding the impact condition:

1) The total mass of the vehicle is 230 kg. Maximum Tensile Stress = 2.44 N/mm2

2) A vehicle travelling at 11.11 m/s (40 km/hr) Factor Of Safety = 1.51

rams into a stationary mass longitudinally.
The CAE model is as follows:
3) The crash impulse time is 0.3s.

 Boundary Conditions:

The front impact members of the vehicle are

constrained.

d) Optimizations:

5. FINAL MATERIAL SELECTION

{Different materials must be compared on the basis of

CAE results and other parameters such as
manufacturability, weight of vehicle then represent in
tabular format.}
 Meshing element size: 3mm.
Materials Selected for Frame:
b) Calculation of impact forces
i. Material 1 Grade, Cross-Section Type, Size
Formulae: ii. Material 2 Grade, Cross-Section Type, Size
iii. ……………….(List down all selected materials)
F = m*a; a = v/t;
6. CAE ANALYSIS OF OTHER PARTS
Where
1) Wheel hub
m=mass, a=acceleration, v=velocity,
Downward force of 1472 N due to weight of the vehicle
t=time, F=force and impact force of 3g N is applied to the wheel hub.

m=230 kg; v=11.11 m/s; t= 0.3 s; F = 0.6*250*9.81

= 1472 N
a=11.11/0.3 = 37.03 m/s2
F impact = 3*250*9.81
F= 230 x 37.03 = 8516.9 N = 7358 N

c) Analysis Results: a) Displacement Analysis :

Max displacement : 0.001 mm
Maximum Deformation = 12.8 mm

The CAE model is as follows:

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 3) IDLER ARM

A force of 150N acting on the tie rod is applied on the

idler arm and the central triangular link.

M → Mass of the vehicle

L → Wheelbase
d → Distance between Center of Gravity and the rear
axle
G → Weight on the front axle
b) Stress Analysis : µ → Coefficient of Friction
Yield strength : 310 MPa B → Width of tyre
Max stress : 28.94 MPa
FOS: 10.71 M=90kg L=1.2m d=0.84m µ=0.6

M g d 90∗9.81∗0.84
G= = = 618.03N
L 1.2

B2 =
Torque required to turn the wheel = ML = Gµ

2
0.054 = 7.07Nm.
√ 8
618.03 * 0.6 *
√ 8
The perpendicular distance between the tie rod and the
2) Wheel axle wheel center is 68mm for the inner wheel and 145mm
for the outer wheel.
A force of 3g N has been applied to the wheel axle
of 7358 N. M L M L 7.07 7.07
Total Force = + = + =150 N
a) Displacement Analysis :
r 1 r 2 0.068 0.145
Max displacement : 0.001 mm
a) Displacement Analysis:

Maximum Displacement = 0.077mm

b) Stress Analysis :
Yield strength : 310 MPa
Max stress : 28.38 MPa
FOS: 10.92

b) Stress Analysis:

Yield Strength = 370N/mm2

Maximum Stress = 124N/mm2
FOS = 2.98

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4) Triangular Link
a) Displacement Analysis:
Maximum Displacement = 0.013mm
b) Stress Analysis:
Yield Strength = 370N/mm2
Maximum Stress = 99.2N/mm2
FOS = 3.72
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CAD Models of all these parts should be shown with the
dimensions at Appendix-1.}
7. VEHICLE VIEWS
Vehicle views should be included at the Appendix-1
with all dimensions as asked (all views given at
Appendix-1 are mandatory). Complete CAD model with
the placement of all components should be shown.
If required more pictures of the CAD model may be
inserted at Appendix-1 (e.g. Both side views if the
sitting height for both drivers is different in case of
adjacent seats, detailed view of subsystems etc.). All
the pictures must be full page pictures at Appendix-1
and can be rotated for better presentation.
If the space of CAE images is felt insufficient in the
document, these may be placed as Appendix-2 at the
end of report with proper captions and picture numbers.
The picture numbers should be referred in the main
document content.
All hand sketches, 2D drawings, prototype images may
be included in Appendix-2.
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 APPENDIX-1 : Vehicle Views

Figure-1 (Isometric View of Vehicle)

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 APPENDIX-1 : Vehicle Views (contd..)

Figure-2 (Front View of Vehicle)

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 APPENDIX-1 : Vehicle Views (contd..)

Figure-3 (Side View of Vehicle)

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 APPENDIX-1 : Vehicle Views (contd..)

Figure-4 (Top View of Vehicle)

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 APPENDIX-1 : Vehicle Views (contd..)

Figure-5 (CAD Model of Frame)

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 CAD MODELS

1) Wheel Axle

2) Wheel Hub

3) Idler Arm

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4) Triangular Link
GUIDELINES
1. The CAD model must be complete for the
presentation in CAD/CAE Report.
2. The document must be prepared in this template
only. Change in format (header/footer/sequence)
will not be accepted. Any heading cannot be
omitted.
3. Document size should not exceed 5MB, whereas
number of pages is not restricted.
4. This format is a 97-9003 word template. Document
must be saved as Team ID_Team
Name_CAD/CAE Report as a separate ‘.pdf’ file.
5. The file must be sent to efficycle.reports@icat.in
before 28th July, 2017 05:00pm. Mail subject name
must be Team ID_Team Name_CAD/CAE Report.
6. Mails not sent with proper subject name or proper
file name, as given above, will be summarily reject
without any prior intimation and it will be considered
as non-submission of document.
effi.saenis.org EFFI-CYCLE 2017
7. No request for deadlines extension shall be
considered.
8. The font must be “Helvetica”, black, 10 size.
HOW TO USE REPORT TEMPLATE
1. Open the report template. File extension is .dot.
9. Save it as word document with document name
Team ID_Team Name_CAD/CAE Report (write
your team ID and Team name here)
10. Now check the file extension. It should be .doc or
.docx.
11. Check that the document has the header and footer
same as given in the template.
12. Start writing your content in the new document
created by you.
13. After the completion of document, check the format
of such as header, footer, 2 columns format,
pictures placement etc.
14. Now save as .pdf file and then submit through email
as mentioned in guidelines above.
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