Design Report - Team Daggers (ID 72787) M.V.S.

R Engineering College
Our design is intended at the production of a simple and low weight roll cage and thus a healthy power-to-weight ratio of the car. Adhering to the popular rear mounted engine design, we hope to have a healthy weight distribution, hence a good, well handling and balanced car.

TECHNICAL SPECIFICATIONS ENGINE

o Bore x Stroke : 84 mm x 64 mm, Single cylinder, Air Cooled o Swept Volume : 338 cc o Rated Power : 8 kW @ 4400 rpm o Max Torque : 19 Nm @ 3000 rpm o Weight of Engine : 30.5 kg

GEARBOX M & M ALFA TRANSMISSION

The gear ratios of the gearbox used are o 1st = 31.48:1 o 2nd = 18.70:1 o 3rd = 11.40:1 o 4th = 7.35:1

o Reverse= 55.08:1

 SUSPENSION o REAR SUSPENSION

Each rear wheel is mounted on a rectangular cross-section swing arm and suspended by twin spring damper assemblies.

o FRONT SUSPENSION
Each front wheel is suspended by a double wishbone arrangement, mounted on a single spring damper assembly. The spring damper assembly consists of a 5-way adjustable triple rate spring, hydraulic shock absorber with a vertical travel of 90mm.

WHEELS
o 12 wheels o 24 Tire outer diameter

BRAKES
o 240 mm dia o 20 mm wide solid discs

STEERING
o Rack & Pinion type.

DIMENSIONS
o WHEELBASE - 66 INCHES o TRACK WIDTH - 60 INCHES o ROLL CAGE WIDTH - 32 INCHES o EXPECTED WEIGHT - 340 KGS

 Target Vehicle Performance

top speed is acceleration rate which seconds.

The target

aimed at would

60kmph with an expected enable 0 to 45kph in 20

The turning circle diameter is estimated at 8 metres. Radius 4 mts The ground

clearance obtained is 8 inches.

The expected deceleration from 30kph to 0 is about 6 metres. Emissions would be controlled by means of the catalytic converter fitted exhaust supplied by Lombardini Kohler. The exhaust would also be passed through a chamber containing a solution of Sodium hydroxide to enable adsorption of Carbon oxide emissions. SUSPENSION The spring damper assemblies have been taken from two wheeler rear suspensions as they are compact and light-weight and offer optimum travel for the weight under contention. Moreover, they are standard parts and hence can be easily replaced.

 CAD Model.

Roll cage design and driver ergonomics

Driver ergonomics:
The driver has been provided with 3 feet of leg length in the cockpit. The drivers knees would have a clearance of 6 inches to the Side Impact Members (SIM). The Overhead hoop extends to more than 15 inches in front from the drivers head thus conforming to the rule book (>12 inches). The highest point of the rear overhead hoop is at 48 inches from the base of the roll cage. For a seat height of 5 inches, the height of the RRH from the base of the seat is at 43 inches (>41 inches) thus conforming to the rule book.

Thus the cockpit is designed with sufficient space for comfortable seating of the driver and simultaneously conforming to the guidelines mentioned in the rulebook.

Rulebook conformance of the parameters.

RRH Right Rear Hoop
The RRH extends vertically behind the drivers seat to a height of 48 inches from the base of the roll cage.

Rear roll hoop lateral diagonal bracing

The RRH LDB begins at 3 inches from the base of the roll cage (<5 inches as specified) at an angle of 36 degrees (>20degrees as specified) to the vertical.

Roll hoop overhead members RHO

The RHO members extend from the RRH and join the FBM (designed in the form of a loop) at a distance of 15 inches from the point of seating of the driver (>12 inches as specified).

Side impact members SIM

The side impact members are placed at a height of 18 from the base of the roll cage. This would translate to 13 inches for a seat height of 5 inches (between 6 and 14 inches as specified).

o ROLL CAGE MATERIAL The material used for the roll cage

is of circular cross section.

Outer dia 1 inch Wall thickness 3.05mm

Carbon Content 0.19%

The roll cage was conceived with a single type of profile as the design would be simple to construct and be economic. The weight of the roll cage is 65kg. Static analysis of the roll cage yielded the following results. The load is placed on the engine mount members located behind the RRH. The load magnitude is 1000N (Approx 120 kgs) for the engine. The load of 1000N is applied on the seat mount members to account for the drivers weight. A load of 350N is applied on the front impact bracing member to account for the load of the steering mechanism and other peripherals.

Maximum stress Maximum Displacement Minimum factor of safety

176,849,600.00N/m2 5.493e000mm 2

Thus, even with the higher limits of weight being imposed, the roll cage is able to sustain the loads with a factor of safety of 2, proving that the design is quite capable and strong.

This particular design was chosen because of the simplicity. o Only 65 joints. o Extremely spacious yet compact. o Easy access to the engine bay. o Convenient mounting of steering and other systems.

 FRONT SUSPENSION
The front suspension consists of a double wishbone mechanism. The action is provided by means of a spring damper assembly belonging to

Bajaj Avenger.
Suspension Travel 90mm. Unsprung mass 60kg overall Camber angle 0 degrees Castor angle 0 degrees

REAR SUSPENSION The rear suspension consists of rectangular cross-section suspended by two spring damper assemblies.

swing arm

Suspension Travel 90mm Unsprung mass 100kg Camber angle 0 degrees Castor Angle 0 degrees

STEERING DESIGN The steering system is a Rack and Pinion type with a turning radius of 4.5m. The rack and pinion type steering system has been employed for better steering effect as compared to the Ackermann link type steering. The design has a number of advantages like a large degree of feedback, direct steering feel, simple construction, light weight and low cost. This system is easy to manufacture, also the anticipated wear can be compensated by means of a spring pre load. Steering radius 4.5m Steering ratio 15.7:1

BRAKE SYSTEM DESIGN

For uniformity and standardisation, the brakes have been employed from Maruti 800. The brakes are disc brakes for all the wheels for effective locking action. POWERTRAIN SYSTEM The engine is rear mounted and is mated to the gearbox from Mahindra

Alfa. The power would be sent to the rear wheels by means of driveshafts emerging from the differential. The fuel tank used has been employed from Honda Activa as it has a capacity of 6 litres as specified in the rule book. The fuel tank would be kept enclosed in a box in order to comply with the splash and spill regulations. Two kill switches of Ski-Doo type would be installed, one on the dash-board and the other above the engine for safety. Air intake is through the stock air filter supplied by Lombardini. BODY PANELS The body panels would be made of a

Jute reinforced resin

in

order to introduce the concept of environment SAFETY EQUIPMENT The safety equipment consists of o 5 point seat belt o SFI approved neck brace o SFI approved arm restraints o SFI approved helmet and goggles o Dry Powder type fire extinguisher.

friendly panelling.

COST

The gross cost of the vehicle including machining charges is approximately Rs 1, 40,000
GO GREEN COMPLIANCE The go green concept has been adopted by passing the exhaust emissions after the catalytic converter through a chamber containing a solution of Sodium Hydroxide. It is known that Sodium Hydroxide is a good adsorber of Carbon Dioxide. This property would be harnessed to make the exhaust emissions cleaner and more eco-friendly.