DAYANANDA SAGAR COLLEGE OF ENGINEERING

BANGALORE

TECHNICAL
FEATURES

ISO

SIDE

VIEWS
TOP

FRONT

ROLL CAGE DESIGN

MATERIAL
TUBINGS

SAE 1018
MILD
STEEL

WALL THICKNESS

3mm

COCKPIT
DIMENTIONS

1000*700m
m2

LENGTH

84.52 in

HEIGHT

31.49 in

WIDTH

61 in

No. OF WELDS

44

WELD LENGTH

46.2 in

TUBE

Od 27mm

TOTAL WEIGHT

70 kg

FRONT ANALYSIS

Material Specification
Material

AISI 1018 Steel

Density

7.7 Kg/m^3

Yield Strength

386 MPa

Tensile Strength

634 MPa

Poisson's Ratio

0.27-0.3

Analysis Results
Maximum
Stress

124.88 MPa

Maximum
Displacement

1.4411 mm

Acceleration

3g

REAR
ANALYSIS

Material Specification
Material

AISI 1018 Steel

Density

7.7 Kg/m^3

Yield Strength

386 MPa

Tensile Strength

634 MPa

Poisson's Ratio

0.27-0.3

Analysis Results
Maximum
Stress

269.557 MPa

Maximum
Displacement

4.4239 mm

Acceleration

3g

SEAT AND ENGINE

ANALYSIS

Material Specification
Material

AISI 1018 Steel

Density

7.7 Kg/m^3

Yield Strength

386 MPa

Tensile
Strength

634 MPa

Poisson's Ratio

0.27-0.3

Analysis Results
Maximum
Stress

19.4926 MPa

Maximum
Displacement

0.3291 mm

Load

146 kgf

SIDE ANALYSIS 1

ROLL OVER ANALYSIS

SIDE ANALYSIS 2

ROLL OVER
ANALYSIS

POWER TRAIN

ENGINE SPECS

Briggs and Stratton

Model 205432/205332
Power = 10HP
Compression Ratio= 8:1
Torque = 18.6Nm at
2600rpm
305 CC
Four Stroke

TRANSMISSION:MAHINDRA CHAMPION ALFA

Gear R

Overall ratio

Max speed kmph

Tractive force (N)

Acceleration(m/s*s )

Gradeability%

1st

31.48:1

12.42

1798.66

5.45

45.56

2nd

18.7:1

20.91

1068.46

3.237

23

3rd

11.4:1

34.3

651.358

1.97

10.12

4th

7.35:1

53.2

419.95

1.27

2.97

rev

55.08:1

7.1

3147.09

9.5366

87.2134

For TIRE DIAMETER 22 inch, max speed at red line rpm is 48.77kmph
For TIRE DIAMETER 24 inch, max speed at red line rpm is 53.2kmph
Therefore selecting 24 inch diameter for the rear tire :
Taking,
N = Transmission Efficiency = 0.8
Mo =Gross mass of the vehicle = 330 kg
Fr=Coefficient of rolling friction for vehicle on dirt track = 0.1

Rpm vs Speed

TRANSMISSION
CHAIN COUPLING

DIAMETER
REAR AXLE

CALCULATIO
NS

MATERIAL

MS1024

MATERIAL

PITCH

12.7mm

SOLID STEEL
8620

NO OF TEETH

15

PITCH DIA

62mm

VELOCITY

8m/s

TORQUE=F
OS x GERA
RATIO x
MAX
ENGINE
TORQUE

REQUIRED
PULL

2138N

T= 2x 55.08x
19
= 2093.04 Nm9
T=(p/16) x t
xdo3

ALLOWABLE
PULL

1137.5

NO OF
STRANDS OF
THE CHAIN

MAXIMUM
PERMISSAB
LE SHEAR
STESS
T

LENGTH OF
CHAIN

1194mm

T=897x 10^6
N/m2
T=2093.04
Nm
2093.04=(3.14
/16)x 897x
10^6 Xdo3
Do3=1.19x 10-5
Do=0.0228
Do= 22.8mm

MAX
DIFFERENCE
BETWEEN 2
CENTERS

550mm

MAX SHEAR
STRESS
DUE TO
ENGINE
TORQUE

897/2= 448.5
N/mm2

Rpm vs
Tractive
effort

SUSPENSIONS
TYPE
: OUTBOARD
UNEQUAL(FRONT) DOUBLE
A ARMS WITH ADJUSTABLE
CAMBER USING BALL
JOINTS
SHOCK ABSORBERS: COIL
OVER DAMPER
ROLL CENTRE HEIGHT : 4
CAMBER ANGLE : 0
DEGREES
CASTOR ANGLE
DEGREES
CASTOR TRAIL
cm
TOE
DEGREES

: +5
:
:

SPRING MATERIAL :

FRONT

REAR

SPRING
STIFFNESS

7.8956 N/mm

11.8435
N/mm

DAMPING
FACTOR

0.3

0.3

DAMPING CO
EFFICIENT

0.377NS/mm

0.565NS/mm

DAMPED
NATURAL
FREQUENCY

1.9078 Hz

1.9078 Hz

DESIGN

2.43
0

CHROME VANADIUM STEEL

WIRE DAIMETER

10 mm

12

MEAN COIL
DIAMETER

80 mm

96

NO OF TURNS

25

20

FREE LENGTH

460.5 mm

454.5

PITCH

17.62mm

21.525mm

SUSPENSION ANALYSER
TOP

FRONT

A-ARM
ANALYSIS

DIVE

CASTE
R Lt.

CASTE
R Rt.

CAMBE
R Lt.

CAMBE
R
Rt.

RC Lt/
RT,in
LT

RC Lt/
RT,in
RT

RC
Ht,
In LT

RC Ht,
In RT

SCRU
B
In LT

SCRU
B
In RT

.000

3.951

3.951

.000

.000

.000

.000

3.997

3.997

.000

.000

-.500

3.955

3.955

.668

.668

.000

.000

4.860

4.860

.127

.127

-1.00

3.960

3.960

-1.098

-1.098

.000

.000

5.704

5.704

.361

.361

-1.50

3.966

3.966

-1.436

-1.436

.000

.000

6.504

6.504

.659

.659

-2.00

3.975

3.975

-1.737

-1.737

.000

.000

7.367

7.367

1.010

1.010

STEERING
STEERING > MODIFIED MARUTI 800 RACK
AND PINION
WHEEL TRACK

67in

WHEEL BASE

58in

STEERING AXIS
INCLINATION (SAI)

12

SCRUB RADIUS

7.8mm

ACKERMANN ANGLE

17

TIE ROD LENGTH

38.29 in

INNER STEERING ANGLE

44

OUTER STEERING ANGLE

31.5

TURNING RADIUS

3.38m

STEERING RATIO

9.7:1

STEERING WHEEL
LOCK TO LOCK

610

Brake Components & Remarks

Components

Remarks

All 4 Disc combination used to

achieve 4 Wheel Lock .

The Disc and Calipers being

used are the same as previous
year. The reason being its
Reliability and to ease up the
Budget. (Spares will be bought
in case any malfunctions.)
This particular combination of
Calipers is chosen due to its
Ease of Mounting Bleeding
points on top.
Bosch Tandem Master cylinder
is used because of its
Compatibility with the Calipers
and BAJA recommends use of
OEM.
Diagonal Braking Circuit Split
used so that braking power is
available on both Axles in case

Disc Used Apache RTR 180

(Rear)
Caliper Used 3Apache RTR
180 (Front) and 1 Honda
Aviator
Master Cylinder Used Maruti
800 Bosch Tandem Master
Cylinder (OEM)
Aluminum Brake Lines,
Hydraulic Brake hoses, Banjo
bolts etc.

BRAKING SYSTEM & CIRCUIT

SPECIFICATION
S

VALUE

DISC DIAMETER
Outer\inner
CAPILER
PISTON/MASTER
CYLINDER
DIAMETER
BRAKE FORCE (N)
STOPPING
DISTANCE
STOPPING TIME

200mm/170mm
20mm/20mm

DECELERATION

2750.55 N
13.516 meter
(54.0 Km/hr)
1.8 +0.3+0.75 sec
(54.0 Km/hr)
8.3235m/s^2

DECELERATION avg.

5.26m/s^2

PEDAL FORCE

40 kg

SPECIFICATIONS
PEDAL RATIO

VALUE
7:1

STATIC AXLE LOAD

(FRONT\REAR)

582.714N/
2654.6N

DYNAMIC AXLE LOAD

(front/rear)

896N/
2341N

WEIGHT TRANSFER

808.48N

BREAKING TORQUE

582.38N-m

TRACTION FORCE ON
SLOPE
CYLINDER PRESSURE

2289.117N

MASTER CYLINDER
LOSSES

0.125cc

7.876MPa

ELECTRICALS

BATTERY
12 V

HEAD LAMP
15W

HORN
10W

REVERSE
LIGHT
3W LED

REVERSE
ALARM
10W

BRAKE
LIGHT
5W

SAFETY & ERGONOMICS

2 Kill switches (ski do type) are fitted at the dashboard and

the top right corner of the vehicle.

SFI & FIA Certified Race Suit, 5 Point Seat belt. Certified
Motocross Helmet, Gloves, Neck Brace, British standard
Goggles & Arm Restrainers.
The figure below suggests that the driver can exit & enter
from the vehicle conveniently within 5 seconds as
suggested in the rule book.

BINOCULAR VIEW

DESIGN FAILURE MODE EFFECTS ANALYSIS

PART

FUNCTION

FALIURE MODELS

PRECAUTIONS

ROLL CAGE

TO PROTECT THE DRIVER

WHEN MATERIAL
REACHES THE ULTIMATE
STRESS VALUE

USE OF AISI 1018 STEEL

HAVING YEILD STRESS
VALUE OF 386 MPa

ENGINE

TO GENERATE POWER

SPARK PLUG FAILURE/

IMPROPER FUNCTIONING

OLD FILTER

REGULAR CHECK OF
SPARK PLUG
FILTER CHANGE

TRANSMISSION

TO TRANSMIT POWER
FROM ENGINE TO WHEELS

IMPROPER LUBRICATION/
UNEXPECTED LOAD

USE OF ISO GRADE OILS.

SUSPENSION

TO ABSORB SHOCKS

WHEN COIL REACHES TO

SOLID LENGTH

PROPER ASSUMPTIONS IN
DESIGNING.

STEERING

TO STEER THE VEHICLE

BREAKING OF TIE ROD

TIE ROD PLACED BEHIND

THE FRONT A-ARMS

BRAKES

TO REDUCE THE SPEED

WHEN REQUIRED AND TO
PANIC STOP

CIRCUIT FALIURE DUE

TO LEAKAGE
WORNOUT BRAKE
PADS

INAPPROPRIATE AIR
PRESSURE
PUNCTURE/TEAR

WHEELS

TO PROVIDE GOOD
TRACTION

BLEEDING THE
BRAKES BEFORE
EVERY RUN
REGULAR CHECK AND
REPLACEMENT

CHECK THE AIR

PRESSURE AT EACH
REFUEL
SPARE TIRES

Rule Book Compliance

Vehicle Statistics
Number of wheels

Transponders

4(not in a straight line)

Orientation

Vertical to frame

64

Width

24 above the track(max.)

Location
108

Length
Drivers weight & height

113.4kg & 63

Top speed

60km/hr
Engine Statistics

Required engine

Roll cage material specifications

Outer diameter

1(min.)

Wall thickness

.12

Carbon content

.18%

B&S

Displacement

338 cc

Power

Miscellaneous

11hp/8 kW

Spark plug

RC12YC

Drivers exit time

5 seconds

Idle speed

1300+/-100

Firewall thickness

.020

22mm

Fire extinguishers

1 litre(min.)

Air filter inlet diameter

Governor setting

3600 r.p.m(max)

Fuel tank capacity

6 litre

Shoulder harness mounting

Exhaust pipe
Exhaust pipe clearance
dimension

Head restraints

450mm of water column

Minimum area

36sq inches

Any length

Density of padding

50-100kg/m^3

100mm(min.)

Minimum thickness

1.5

Head clearance from seat

41

Head clearance from helmet

Battery Requirements
Battery

Drip pan diameter

Exhaust System
Mufflers Back pressure

7 to 9

12V, 44Ah

VARIATIONS IN DESIGN
2012

2013

Anti Ackerman steering

Ackerman steering geometry

Engine Mounting: Direct Coupling

Chain Sprocket is used

A Bumper was provided

No bumper is provided

Bolt and nut pivot was used

Ball Joint pivot is used

Equal and Parallel A-Arms

Unequal and parallel A-Arms

Tie-rod was in front of the A-Arms Tie-rod is behind the A-Arms

Tyre size: Front 21in, Rear 22in

Tyre size: front 22in, Rear 24in

INNOVATIONS
INDEPENDENT FENDERS-The fender is a removable
attachment to the A-arms of the suspension which help
to block dirt & sludge away from the driver. It is
mounted on the A-arms using pipe brackets hence
avoiding drilling of any holes. The assembly is spring
loaded allowing it to undergo slight deflections and not
making it rigid and prone to failure.

VARIABLE CHAMBER MECHANISM - The variable camber mechanism is a

modification in the front suspension design which will allow us to vary the
camber angle at will. This is done through using adjustment bolts which will
help vary the distance between the upper knuckle joint and the chassis.
Camber can be varied in test runs and the optimum camber can be decided for
the particular condition.

MARKETING
&
SPONSORSHIP

SOCIETY OF AUTOMOTIVE ENGINEERS

(SAE)
A non-profit organization based at Detroit, USA
Working with a mission to enhance human capability of Mobility Engineering
professionals air, land and sea.
It strives to achieve it through

Establishing engineering standards

Professional Development Programmes
Capturing the latest technology and trends
Research publications
Seminars & Conferences APAC, SIMC, etc.
Student Development Programmes
Student Convention
BAJA SAE
Formula SAE
AeroDesign

The society has over 100,000 registered members across the globe. It operates globally
through its national chapters and affiliations with other bodies such as FISITA, etc.
The Indian chapter contributes maximum number of members 25000 registered
members

INDUSTRIAL AFFILIATION OF BAJA

SAEINDIA
Ever since its inception, the event has been
well received by the industry. Some of the
associates of BAJA SAEINDIA include:
Anand Automotive Systems
Gabriel
GM India
HCL
Ansys
ARAI
Ashok Leyland
AVTEC
ICAT
ITW Chemin
JK Tyres
John Deere
Boeing
Bosch
Bharat Petroleum
Brakes India
Johnson Matthey
Liugong
Lombardini
Cumminsa

Dassault Systemes
Delphi
Mahindra & Mahindra
Mahindra Navistar
Maruti Suzuki
NATRIP
EASI
Eaton
EMITEC
ETAS
Precimaxtech
PTC
Sundaram Clayton
Toyota Kirloskar Motors
FIAT
Fleetguard
Force Motors
FORD
TVS Motors
UCAL Fuel
Varroc
Volvo India
ZF Steering

SAE INDIA BAJA

Baja is an inter-collegiate design

competition organized by the Society of

Automotive Engineering (SAE)
Provide Indian students with a
standard platform to showcase their
talent and potential not only in terms of
design and engineering, but also their
capability for team-work, entrepreneurial
skills and management.
The contest challenges each team to
function as a firm, whose task is to
design, fabricate, market and race-off an
off-road vehicle that will be evaluated on
a variety of manufacturing angles.
The vehicles are judged based on their
ability to maneuver and transverse harsh
off-road racing course while not
succumbing to the rigors of it.

TEAM KASHPIERS @ DSCE

Started in May, 2010.
With a mission of meeting the necessities and requirements of the
industry by gaining practical knowledge and hands-on-experience.
Amongst the Top-3 Collegiate Clubs in the Nation in terms of
Members Strength, with 800+ members as of today.
One of the most active Collegiate Clubs in the Country with atleast
one event in a fortnight!
Hosted a NATIONAL EVENT in just 14 months since formation.
XXX, Princeton Review , Global Solution , Briggs and Stratton are
few of our previous years sponsors.

STATUS UPDATE
ZONE WISE DISTRIBUTION
39

10

59
84

68

EAST
WEST
NORTH
SOUTH
CENTRAL

THE BAJA STORY

300
250
198
146

106
54

2009

130

75

80

2010

2011

100

2012

2013

BAJA MAIN EVENT

VIRTUAL BAJA

MEDIA PRESENCE

SPONSORSHIP BENIFITS

The Company will gain ETHICAL value and provide moral support for the budding
engineers of the future.
Company name will be placed with Team name in all BROCHURE, college
NEWSLETTER(Teckriti) , ANNUAL COLLEGE FESTS & AUTO EXPOS (Bangalore).
BANNERS, PORSTERS, FLYERS of specific sizes will be displayed on campus
The event is sponsored by various industrial giants like MAHINDRA , JK TYRE, ANSYS
Print, Television, Radio media like DNA, DECCAN HERALD, TV 9 supporting the Team
The company name will be published in the team WEBSITE.
The company name will be displayed on the car at all times, bring it into the limelight.
The competition will be witnessed over 5000s of graduating engineers attracting them
to the company
The company will be displayed on the PARKING SLIP which will have a distribution rate of
600 per day.
The event will be witnessed by various GM, CEO & MDs of the public and private
sector companies.

SPONSORS SPACE

FRONT VIEW
SIDE VIEW
The company will also feature on the helmets, Team T-shirts, Driver uniform,

Pit area, Bags, Business Cards & College Magazines

The sponsoring company can use the college premises for advertisement and
publicity

COST REPORT
Bill Amt in Rs

Currently

1. VIRTUAL REGISTRATION

15,000/-

Sponsored by college

2. BAJA REGISTRATION

35,000/-

Sponsored by college

3. MATERIAL (CHROMOLY OR MILD STEEL 1024)

35,000/-

4. FORGING

3,000/-

5. TOOLS

25,000/-

6. FABRICATION

25,000/-

7. STEERING

5,500/-

8. SUSPENSION & ASSEMBLY

30,000/-

9. BRAKES

16,330/-

Sponsored by TVS

10. TYRES

60,000/-

Sponsored by CEAT

11. NUTS&BOLTS

3,000/-

12. FIBERGLASS

5,000/-

13. ELECTRICALS

4,000/-

14. PAINT

5,000/-

15. TRANSMISSION

25,000/-

PARTICULAR

16. ENGINE (SERVICE)

6000/-

17.TRANSPORT TO VENUE ( WITH INSURANCE)

25000/-

18. TEAM TRAVEL AND ACCOMODATION

60000/-

TOTAL

3,82,300

Sponsored by Minda

Sponsored by B&S

MAJOR COST BREAKUP

MISCELLANEOUS
16%
SAFETY
13%
ENGINE & DRIVE
35%

ELECTRICAL
BRAKES
2%
6%

FRAME & BODY

7%

SUSPENSION
8%

STEERING
2%

GRAND TOTAL OF THE PROJECT : 3,82,300

.

TRANSMISSION
11%

Monetary Assistance Fund our project where we both benefit on the long run. Your company logo
will be placed on various parts of the vehicle as well as on the drivers apparel and helmet . PUBLICITY.
Parts & accessories - Numerous parts are required in building the ATV like shockers , welding rods ,
frame /chassis metal , steering, speedometers, electrical systems, ignition systems and other
components.
Any material assistance is appreciated and the company logo will be placed on the vehicle.
Benefits depends one the cost of the part/material.
Technical Assistance Our design team will require technical assistance frequently in order to solve
real time problems . Your help will be greatly appreciated as technical sponsor and company logo will be
advertised on the vehicle .Benefits depends on the level Assistance.
Travel sponsors- our entire team will require to travel to various destinations across the country to
compete and exhibit our vehicle .Also the cost of 20 people traveling for the competition. All Benefits will
be provided to the sponsor. They will fall into the silver sponsor category.
Transport sponsor- The team will require frequent delivery of parts for various places. A major portion
of the cost will be incurred on transporting the car to the venue. This sponsor will fall into the Silver
sponsor catogery
Media Sponsors The entire team and the vehicle will have exclusive media coverage during the
making as well as participation in the rally which will propagate your companys presence as a sponsor
.Social, Television, Radio, Print .

NOTE- Details on the size, location, Frequency of distribution of banner, posters, flyers, brochures,
newsletters, advertisement spaces and social media publicity will be provided.
Regular updates will be provided to all sponsors.

Name to be
placed before
team name

Flex Banners
Company Logo
in the PIT
LANE

Part of
placement &
training
program
Hyperlink to all
associated
sites

Name of Co.
on the
brochure
Logo on Team
Apparel

TITLE

PLATINUM

DIAMOND

GOLD

SILVER

BRONZE

8ft x 6ft

8ft x 4ft

6ft x 6ft

6ft x 4ft

4ft x 4ft

3ft x 2ft

FRONT

BACK

SIDE

SIDE

SIDE

WORKSH
OP

FIFTH

SIXTH

FIRST

SECON
D

THIRD

FOURTH

FRONT
BACK
INSIDE

FRONT
BACK
INSIDE

FRONT
BACK
INSIDE

BACK
INSIDE

INSIDE

INSIDE

POWERTRAI
N

ELECTRICALS &
BRAKES

1-Hansel P

1-Apoorv B

2-Vinay SN

2-Avijit P

3-Dheeraj J
4-Huzefa P

DESIGN

5-Divyanshu P

1-Suhas VR

DESIGN

2-Sagar M
3-Abhishek M

MARKETING
1-Mohit M

SUSPENSION
1-Varun J

2-Deepak K

STEERING

2-Anurag S

1-Pavan K

3-Gaurav A

2-Girish P

4-Siddhart P K

THANK YOU

TEAM KASHPIERS