BVCOE

BHARATI VIDYAPEETH COLLEGE OF ENGINEERING, SECTOR7, C.B.D, BELPADA, NAVI MUMBAI-400614

FORMULA STUDENT, GERMANY

INTRODUCTION
We would like to have your attention to a unique project in co-operation of the Bharati Vidyapeeth College of Engineering (BVCoE). NAVI MUMBAI. The BVCoE SAE Collegiate Club, which consists of over 60 students, designs, analyses, and tests not only Formula racing cars but also All-Terrain-Vehicles (ATVs) completely under their own supervision. Formula student is the largest design competitions for universities worldwide, with over 70 universities, coming from all over the world, compete in the event. The Collegiate Club of BVCoE has formed a team of hard-working students for the competition FORMULA STUDENT, GERMANY (HOCKENHEIM) 2012. These students with their sustainable design concept are bound to stand-out extraordinarily in the competition, and are aiming for best performance in every aspect of the event. In this file you will find the information about the competition, our design concept of the car and of course the advantages when sponsoring the team for the competition.

TEAM LEADER Mr. Prateek Vishwakarma E-mail: prateek_pv@yahoo.co.in

TEAM BUSINESS AND MARKETING HEAD Mr. Jasdeep Singh E-mail: jasdeep.jas15@gmail.com

ABOUT BVCOE
Bharati Vidyapeeth College of Engineering (BVCOE), Navi Mumbai is one of the institutions from the pool of institutions and organizations established under the Prestigious Bharati Vidyapeeth University. It was established in 1990 by Honorable Dr. Patangrao Kadam, and since its establishment it has grown into one of the leading educational institutes in Navi Mumbai. In the span of seventeen years the College has earned appreciation for its excellent infrastructure, well equipped laboratory facilities, qualified faculty and hence the outstanding results of students.

BVCOE, NAVI MUMBAI

The college is affiliated by University of Mumbai and offers four year Undergraduate Programs leading to Bachelor of Engineering (B.E) Degree of University of Mumbai, in various disciplines as given below.
Chemical Engineering (Intake 60) Mechanical Engineering (Intake 120) Computer Engineering (Intake 60) Electronics and Telecommunication Engineering (Intake 60) Information Technology Engineering (Intake 60) Instrumentation Engineering (Intake 60)

It is situated in the lap-of-nature, surrounded by the green Parshik hills and in the midst of a quiet residential area. Its close proximity to Kharghar railway station and Sion-Panvel highway helps student in easy reach to the college, and Thane-Belapur belt, Rasayani, MIDC, and Taloja industrial areas gives student the necessary exposure to industrial activities and facilities.

ABOUT THE COMPETITION

Formula SAE is a student design competition organized by the Society of Automotive Engineers (SAE, also known as SAE International). The competition was started back in 1978 and was originally called SAE Mini Indy. The concept behind Formula SAE is that a fictional manufacturing company has contracted a student design team to develop a small Formula-style race car. The prototype race car is to be evaluated for its potential as a production item. The target marketing group for the race car is the non-professional weekend autocross racer. Each student team designs, builds and tests a prototype based on a series of rules, whose purpose is both ensuring on-track safety (the cars are driven by the students themselves) and promoting clever problem solving.

Formula SAE encompasses all aspects of a business including research, design, manufacturing, testing, developing, marketing, management, and fund raising. Formula SAE takes students out of the class room and puts them in the real world. The Formula SAE Competition Series consists of the following seven (7) competitions: 1. Formula SAE Michigan held in Michigan, USA and organized by SAE International. 2. Formula SAE Lincoln (formerly California), held in Nebraska, USA and organized by SAE International. 3. Formula SAE Australasia held in Australia and organized by SAE Australasia 4. Formula SAE Brazil held in Brazil and organized by SAE Brazil 5. Formula SAE Italy held in Italy and organized by ATA 6. Formula Student held in the United Kingdom and organized by IMechE 7. Formula Student Germany held in Germany and organized by VDI.

FORMULA STUDENT, GERMANY (FSG)

Formula Student is also a F1 racing competition sanctioned by the collaborated committee of SAE and IMechE. It is yearly organized by Verein Deutscher Ingenieure (V.D.I.) at Hockenheimring in August month. The prototype race cars appearing in the competition are judged in a number of different events. The Types and the points schedule for most Formula SAE events are:
Design Event Cost & Manufacturing Analysis Event Presentation Event Acceleration Event Skidpad Event Autocross Event Fuel Economy Event Endurance Event Total Points Possible 150 100 75 75 50 150 100 300 1,000

In addition to these events, various sponsors of the competition provide awards for superior design accomplishments. For example, best use of E-85 ethanol fuel, innovative use of electronics, recyclability, crash worthiness, analytical approach to design, and overall dynamic performance are some of the awards available. At the beginning of the competition, the vehicle is checked for rule compliance during the Technical Inspection. Its braking ability, rollover stability and noise levels are checked before the vehicle is allowed to compete in the dynamic events.

FSG 2009

THE DESIGN CONCEPT

The design concept of Formula SAE and Formula Student, as its name suggest, comes from the Formula ONE or F1 concept and technology. High-performance, low-weight and high power these are some of the qualities which are expected to be found in a formula racing styled cars. Perfect Aerodynamics and streamlined bodies increase the drag-force of the car to such extent that it seems that the car is stuck on the road. The BVCoE team is tryin the same to achieve a formula car which can perform to the likes of the Formula cars. For achieving the likes of the performance of Formula cars, it should have the parts and technology of Formula cars. The Formula car designed by the BVCoE team will be the following main structure: Main chassis Monocoque body Engine Suspension Wheel and Brakes Aerodynamics Weight

Each above component is discussed in the following pages.

THE MAIN CHASSIS

The main chassis is the main structure on which the whole formula car is made. In the case of vehicles, the term chassis means the frame plus the "running gear" like engine, transmission, driveshaft, differential, and suspension. For formula cars the chassis must be as light and as strong as possible. The design of the chassis should be such that the deformation of the car is to be kept very less or negligible and simultaneously holding every system of the running car. Below is the CAD Drawing of the chassis made by the team. It has been made as according to the rules given by the competition authorities. The chassis is made with Chromolloy Steel 4130 or Steel T-45. The chassis went through a rigorous stress analysis process in which effect of load on every member was checked and changes were done wherever necessary.

The Side and Top view of the chassis.

It can be seen in the side view that the Roll over loop has been given sufficient height to provide safe clearance to the drivers head as according to the FSAE Rules.

The width of the chassis, as seen in this top view, is kept as lean as possible to keep the air-drag minimum.

THE MONOCOQUE BODY

Monocoque is a construction technique that supports structural load by using an object's exterior, as opposed to using an internal frame or truss that is then covered with a non-load-bearing skin or coachwork. The word monocoque comes from the Greek for single (mono) and French for shell (coque). The technique may also be called structural skin, stressed skin, unit body, unibody, unitary construction, or Body Frame Integral (BFI). In formula technology monocoque body comes in the form of body panels, which serve the purpose of giving the car a smooth and strong covering panel which fits on the chassis and makes the whole unit as one piece. Monocoque body panels of a formula car also include side pods and aero wings which improve the air intake and aerodynamics of the car respectively. The team after thorough research decided of light-weight aluminium alloy or carbon-fiber sheets for the body panels.

Monocoque body panels of a professional formula 1 race car.

THE ENGINE AND TRANSMISSION

The engine must be a four-stroke, Otto-cycle piston engine with a displacement no greater than 610cc. An air restrictor of circular cross-section must be fitted downstream of the throttle and upstream of any compressor, no greater than 20mm for gasoline engines or 19mm for ethanolfueled engines. The restrictor keeps power levels below 100 hp in the vast majority of FSAE cars. Most commonly, production four-cylinder 600cc sport bike motors are used due to their availability and displacement, however many teams have also used smaller V-twin and singlecylinder engines. Considering the limit of power-to-weight ratio and also the requirement of fast acceleration the team selected the 559 cc inline four cylinder engine. The transmission serves the purpose of effectively transmitting the power of engine to wheels in a controlled manner. The formula cars are famous for the pedal shifters which replace the use of the gear stick and ensure fast and efficient gear shifting.

ENGINE

THE SUSPENSION
Suspension is another most important part of the car as it makes the car stable and determines its ability to steer efficiently. Most of the cars in the Formula SAE competition opt for independent suspension system in both rear and front of the car. The team selected the universally accepted Double Wishbone suspension system for its ability to give a good ratio of stability and maneuverability.

DOUBLE WISHBONE SUSPENSION

WHEELS AND BRAKES

Wheels and brakes also form and integral part of the car as on a formula race track the formula car goes through the acceleration and brake cycles thousands of times so efficient braking and good tire grips are very important. Formula cars are famous for employing non-treaded tires called as slick tires. Ventilated Disc brakes are used for frequent braking in the race and better control of the car at high speeds. The team has selected the ventilated disc brakes in both front and rear and sets of both high performance race tires and slick tires.

THE AERODYNAMICS
The aerodynamics of the car shows how fast or stable the car can run at high speeds. With usage of massive wings and undertrays and front wings the downforce of the car can be increased further to increase the stability of the car at high speeds. But there are few regulations or requirements on aerodynamics. Most teams do not build aerodynamic packages as the speeds involved in FSAE competition rarely exceed 60 mph (97 km/h), and design judging tends to frown upon aerodynamic parts that do not have definite test data, usually in the form of wind tunnel testing or at least computational fluid dynamics analysis. Therefore most cars that do utilize aerodynamic downforce tend to develop their entire car around the aerodynamic package, including massive wings and undertrays. The benefit of a well-developed aerodynamic package is evident; depending on how fast the course is, the slowest aero-package cars sometimes run several seconds per lap faster than any of the non-aero cars. But, on windy days, at the drag strip, or especially in the fuel economy event, aero cars can suffer significantly. After thorough consideration the team decided to not to use the aerodynamic devices like wings as of their requirement of data test sheets in the competition.

WEIGHT OF THE CAR

There is no weight restriction. The weight of the average competitive Formula SAE car usually weighs less than 500 lb. (230 kg) in race trim. However, the lack of weight regulation combined with the somewhat fixed power ceiling encourages teams to adopt innovative weight-saving strategies, such as the use of composite materials, elaborate and expensive machining projects, and rapid prototyping. In 2009 the fuel economy portion of the endurance event was assigned 100 of the 400 endurance points, up from 50. This rules change has marked a trend in engine downsizing in an attempt to save weight and increase fuel economy. Several top-running teams have switched from high-powered four-cylinder cars to smaller, one- or two-cylinder engines which, though they usually make much less power, allow weight savings of 75 lb. (34 kg) or more, and also provide much better fuel economy. If a lightweight single-cylinder car can keep a reasonable pace in the endurance race, it can often make up the points lost in overall time to the heavier, high-powered cars by an exceptional fuel economy score. The tentative weight of the teams car will be in the range 330 to 350 kg, thus ensuring good power-weight ratio and enough space for involving heavier power machinery for the car.

THE COST PLAN

The following is cost plan (customs excluded) for the competition FSG 2012. SR.NO A PARTICULARS Components COST (INR) 8,80,000

Brake system Engine and ECU Drive Train Assembly Frame and Body Instruments and Wiring Steering System Suspension and Shocks Wheels and Tires Miscellaneous, Fit and Finish

35,000 3,00,000 50,000 2,50,000 20,000 45,000 60,000 70,000 50,000

B C D E F G

Team Transportation and Accommodation Car and Equipment Transportation Competition Registration Fees Testing and Training Tools and Equipment Marketing Expenditure

8,00,000 4,00,000 80,000 50,000 50,000 80,000

TOTAL

23,40,000

THE SPONSORSHIP PLAN

SUPPORTER/ BRONZE SPONSORS (1, 00,000 - 2, 00,000 `)

2 small sized logos on the car or on the part provided by the company 1 small sized logo on the teams uniform Publication of the company (through a small sized logo) on the proposed official site of the team

SILVER SPONSORS (2, 00,000 - 4, 00,000 `)

All benefits of bronze sponsorship 2 medium sized logos on the car on highly visible area of the car 2 small sized logo on the teams uniform Publication of the company (through a medium sized logo) on the proposed official site of the team

GOLD SPONSORS (4, 00,000 6, 00,000 `)

All the benefits of silver sponsorship A large sized logo on the car on the highly visible area of the car 2 medium sized logo on the teams uniform and a small sized logo on the driver helmet Publication of the company (through 2 large sized linked logos) on the proposed official site of the team Extra Publication through the presence of the companys banner at colleges events and annual festival Presence of medium sized logos on exhibition panels, wherever the team and/or the car is exhibited Company can directly present itself to the participating students as an employer, for example for distributing information brochures and giving business presentations

GRAND/ PLATINUM SPONSORS (>7, 00,000 `)

All the benefits of the gold sponsorship Large sized logos on prominent and highest visible areas of the car Large sized logos on the teams uniform and driver helmet Publication of the company (through large sized logos) on the every page of teams proposed official site Company gets exclusive rights to decide the teams car name and the color of the car Students will be encouraged to do industrial visits to the company and thus discover the working of the company The employees of the company will be invited at the testing day of the designed car Whenever your company if organizing an event or participates in an exhibition, the company has the possibility to have the car and team members at the event/ exhibition

FOR MORE INFORMATION,

Please Contact: Mr. Prateek Vishwakarma (Team Leader) Email: prateek_pv@yahoo.co.in , Phone no: (+91)/ (0)9664352663 Mr. Jasdeep Singh (Team Business and Marketing Head) Email: jasdeep.jas15@gmail.com , Phone no: (+91)/ (0)9920098686

Visiting address: Mechanical Department, Bharati Vidyapeeth College of Engineering Sector- 7, C.B.D, Belpada,

Navi Mumbai - 400614