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Team Stratos BAJA Preliminary Design Report 2010

Team Stratos BAJA Preliminary Design Report 2010

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Published by Manish O
It is a preliminary design report. So.. Don't get too hung up on the details.
It is a preliminary design report. So.. Don't get too hung up on the details.

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Published by: Manish O on May 21, 2010
Copyright:Attribution Non-commercial

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08/15/2013

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1
 Team Stratos B.I.T
Design Report
Manish.O
Team Captain
Dr. T. Jagadish
Faculty Advisors
ABOUT THE EVENT
The objectives of the Baja SAEINDIA 2010 competitionare to design and manufacture a fun, versatile, safe,durable, and high performance off road vehicle.Team members must ensure that the vehicle satisfiesthe limits of set rules, while also generating financialsupport for the project, and managing their educationalresponsibilities.This vehicle must be capable of negotiating the mostextreme terrain with ease.
INTRODUCTION
Baja SAEINDIA is a collegiate design competitionsponsored by the Society of Automotive Engineers (SAE)that attracts engineering student teams from all over India.Each team’s goal is to design, build, test, promote, andrace a prototype of a single seat off-road vehiclehypothetically intended for production and eventual saleto the weekend off-road enthusiast.Team Stratos comprises of 20 students of mechanicalengineering from the
BANGALORE INSTITUTE OFTECHNOLOGY, BANGALORE.
Team Stratos’ main design objective was to ensure itsvehicle design is able to complete all tasks without anybreakdowns, whilst being an appealing vehicle topotential customers.Team Stratos met its design objectives by dividing thevehicle into major component subsystems. The teamwas divided into groups, with each group beingresponsible for a specific subsystem that was designedaccording to the team objectives and within set rules.An open source approach was adopted for all thedesigning and analyzing work. Hence, contributions fromother members of the collegiate club were alsoencouraged.
INNOVATION
RACE ERGONOMICS – A wide field of vision will beincorporated by increasing distance between A-pillars.This will allow ease of maneuverability and corneringability.DRIVER ERGONOMICS – A spacious driver cabin willallow easy ingress and egress from the vehicle and ariding position designed for maximum driver comfort.FRAME - A light and rigid chassis will ensure goodvehicle handling while increasing driver safety in a race.SUSPENSION – An independent double wishbonesuspension at front and rear intended to give acomfortable ride whilst not compromising on shockabsorption in an off-road terrain.STEERING – Rack & pinion steering assembly tominimize force feedback from track conditions. Discbrakes installed in front will enable quick braking.POWERTRAIN – Spacious engine bay for easyserviceability and repairs under intense track conditions.Directly coupled (4+1 reverse) transmission.
MAIN SECTION
FRAME DESIGN
Initially the general shape of the frame was sketchedusing sketcher software (Google Sketch Up). Differentshapes and sizes were considered. Finally a frameshape was chosen with form and function in mind. (Fig 1)Before the chassis design was finalized, a 1:1 mock upof the frame was built out of bamboo.The mock up allowed the team to visualize the frame in3D, as well as mock up the powertrain, steering, andbrake systems to ensure that there is adequate space.
 
21 (Fig 1)(Fig 2)Basic geometrical calculations were done to obtainvehicle dimensions. All main chassis members werescrutinized to ensure compliance with set competitionrules. An optimum riding position and driver leg roomwas finalized.Position of steering wheel, control pedals, side impactmembers, and seat were considered with a view tomaximize cabin room and driver comfort.Horizontal spacing between A-pillars was maximized atthe base to improve the driver’s field of vision.Engine bay area was enlarged to fit powertrain membersand leave space for easy servicing.Different hard points for location of suspension, springs,steering, etc were considered. (Fig 3)(Fig 3)After studying the mock-up and making necessarychanges to the frame, a CAD model of the frame wasmade with a view to perform finite element analysis andtesting. (Fig 4, 5, 6)(Fig 4)
 
3(Fig 5)(Fig 6)In the CAD model, the final geometrical specifications of the vehicle were implemented.Adequate bracing was given to reduce stresses in mainchassis members and ensure proper transmitting of forces to chassis. All corners of the roll cage werebraced as shown.The CAD model was analyzed using ANSYS FEAsoftware for static analysis under self-weight, frontalimpact, side impact, and roll-over impact as well asnatural frequency and torsion analysis. FEA model usedbeam elements.Under self-weight, the frame was deforming very little.Stress was maximum in the front of the roll hoops andfirewall members. The firewall itself will act as additionalbracing here. (Fig 7)
1
MNMX
XYZ 0.019307.038615.057922.07723.096537.115844.135152.154459.173767
JUN 4 200920:22:57NODAL SOLUTIONSTEP=1SUB =1TIME=1USUM (AVG)RSYS=0DMX =.173767SMX =.173767
 (Fig 7)In the
frontal impact
analysis, a 5KN force was used asit was assumed impact would be with a stationary object.The deformation was minimal and proved the frame wasrigid enough to withstand a crash. (Fig 8)
1
MNMX
XY
 
Z 0.019844.039688.059532.079376.09922.119064.138908.158752.178595
JUN 6 200915:58:05NODAL SOLUTIONSTEP=1SUB =1TIME=1USUM (AVG)RSYS=0DMX =.178595SMX =.178595
 (Fig 8)In
side impact
, hypothetically with another Baja vehicle,a 3KN force was applied to the side impact member.Deformation was again in the roll cage. (Fig 9)
1
MNMX
XYZTEAM STRATOS-BIT0.013972.027943.041915.055887.069858.08383.097802.111773.125745
JUN 6 200915:26:44NODAL SOLUTIONSTEP=1SUB =1TIME=1USUM (AVG)RSYS=0DMX =.125745SMX =.125745
 (Fig 9)The
natural frequency
was analyzed using modalanalysis in 3 sub-steps. Maximum vibrations andconsequently displacements were occurring again in theroll cage members. Deformation was within limits, butpowertrain etc will be well isolated using rubber bushingsto cancel vibrations. (Fig 10, 11, 12)

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