TEAM GEAREDUP - 96745 19

th
AUGUST 2011
DKTES Textile and Engineering Institute,
Ichalkaranji
Kolhapur.
SAE BAJA - 2012
Team Captain
Saddam Hussain
(B.E. Mechanical)
Faculty Advisor
Prof. Mr. A. R. Balwan
RULE BOOK IMPORTANT PARAMETERS
PARAMETER ALLOWED SELECTED
TRACK WIDTH 64 INCH 46 INCH
WHEEL BASE 108 INCH 67 INCH
MAXIMUM SPEED 60 Km/Hr 45 Km/Hr
MATERIAL STRENGTH 365 Mpa 480 Mpa
DRIVER HEAD CLEARANCE 6 Inch 6 Inch
VEHICLE MUST BE SAFE AND EASY TO RIDE.
EASY ACCESSIBLE COCKPIT.
AESTHETICALLY GOOD .
VERY LESS UTILISATION OF READYMADE COMPONENTS.
NO ALTERATION WITH THE ENGINE.
DRIVER SHOULD BE EQUIPPED WITH SAFETY GEARS AND MEASURES.
PROPER FUEL STORAGE WITH DRAINAGE SYSTEM.
INDEPENDENT BRAKE CYLINDERS FOR FRONT & REAR WHEELS.
PROPER & SAFE CLEARANCES.
CHASIS
DIMENSIONS:
Length= 87 inch Height= 48 inch
Width= 33.02 inch At front end= 13.4 inch At rear end= 15 inch

MATERIALS: Steel IS 1239

WEIGHT:



WEIGHT APPROX. :- 68 KG
PURPOSE : Material -- High yield strength and cost which is moderate.
Roll Cage Simple design will lead easy manufacturing with future
modifications and effective utilisation of space.

ADVANTAGE : More space for the driver to easily enter and exit the vehicle.
Suitable for long and bumpy terrains.

Side impact members BENDED- More space & clearance
between the member and knees for SAFETY.



OUTER DIAMETER: 33 mm
THICKNESS : 3 mm
ERGONOMIC AND AESTHETIC VALUES
SPACIOUS COCKPIT
COMFORTABLE HEIGHT & INCLINATION OF STEERING WHEEL
SMALL WHEELBASE FOR EASY MANEUVERABILITY.
SIM (SIDE IMPACT MEMBER) MODIFIED FOR INCREASING
COMFORT OF THE DRIVER.
SIM
WHOLE WEIGHT OF CHASIS SUPPORTED OVER 2 PARALLEL L-CHANNELS.
INCLINATION OF 6 DEG. AT FRONT END OF LFS NATURAL WHEEL TRAVEL
DURING FRONT HUMP ENCOUNTER.
EVERY PART HAS BEEN DESIGNED UNDER APPROPRIATE PROPORTION.
WELD JOINTS REPLACED WITH BENDS TO ENHANCE STREAMLINE
EFFECT.


L-CHANNEL
FRONT
TOP
SIDE
6 Deg
FEA RESULTS & CONCLUSION
LOAD INFORMATION
FRONT IMPACT AT FULL SPEED OF 60 Km/hr.
MESH INFORMATION
FEA
FRONT IMPACT SIDE IMPACT
OTHER PARTS
REAR ARM FRONT A-ARM
FRONT HINGE
REAR HINGE
FRONT VIEW SIDE VIEW
ISOMETRIC VIEW TOP VIEW
48 inch
66.8 inch
46 inch
12 inch
TRANSMISSION
GEARBOX : MAHINDRA & MAHINDRA ALPHA CHAMP
Having 4 forward + 1 reverse gear with built in differential and universal joint .
Configuration of our vehicle would be REAR ENGINE REAR WHEEL DRIVE

CALCULATIONS :
ENGINE SPECIFICATIONS: Lombardini LGA 340

Rated Power: 8 kW at 4400 rpm Max Torque: 19 Nm at 3000 rpm

TYRES : WHEELS :
DIAMETER 24 INCHES , WIDTH 12 INCH R15-SKODA
ATV TIRES
1
ST
- 6.8 TO 10.06 Km/hr
2
ND
-11.55 TO 16.94 Km/hr
3
RD
- 18.94 TO 27.78 Km/hr
4
TH
- 29.38 TO 43.10 Km/hr
REVERSE 3.92 TO 5.75
Km/hr
BRAKES
REAR : Internal Expanding Shoe Brakes
FRONT : Disc Brakes



Weight falling on each rear wheel 48 kg

CHARACTERISTICS

Independent Hydraulic reservoirs

Four wheels must lock at the same
time.

Produce required force to stop the
vehicle at the maximum speed.


SR
NO.
V
(km/hr)
R F(braking)
(N)
f(deceleration)
(m/s2)
1. 50 1 808.525 2.99
2. 50 .55 1281.86 4.74
3. 50 .45 1473.56 5.45
4. 50 .40 1593.66 5.89
5. 50 .35 1899.73 7.03
SR. NO. V(Km/hr) f (m/s2) R R(N) S(m)
1. 50 2.99 290.63 32.26
2. 50 4.74 460.73 20.35
3. 50 5.45 529.74 17.7
4. 45 4.74 460.73 16.48
5. 45 5.45 529.74 14.33
6. 45 7.03 683.32 11.11
7. 35 5.45 529.74 8.67
8. 35 5.89 572.51 8.02
9. 35 7.03 683.32 6.72
SUSPENSION
SUSPENSION DEMANDS: Ground clearance to be 11-12 inches
PARAMETER
spring rate 19.71 N/mm
Total number of
coils
15.00
Number of active
coils
13.00
Wire diameter 11.00 mm
Free length 390 mm
solid length 150 mm
solid load 4827.22 N
FIGURE FROM SUSPROG SOFTWARE
TYPE- 14 Rack and Pinion system
RACK C- FACTOR - 52.00
STEERING RATIO- 12.10

TURNING RADIUS- 3.6m
( tire contact centre) LH/RH

STEERING
For steering calculations we used Susprog software
SR . NO. A(degree) L1(inch) r 1(m) L2(inch) r 2(m)
1. 30 70 22.07 60 18.9
2. 45 70 14.72 60 12.62
3. 60 70 11.04 60 9.47
4. 90 70 7.37 60 6.32
5. 120 70 5.54 60 4.75
6. 135 70 4.93 60 4.22
7. 150 70 4.44 60 3.81
8. 210 70 3.19 60 2.74
9. 240 70 2.80 60 2.40
10. 300 70 2.26 60 1.94
11. 360 70 1.91 60 1.63
ELECTRICAL SYSTEMS
IGNITION SWITCH 12v 44Ah BATTERY HORNS
TAIL LIGHT HEAD LIGHT
ENGINE MOUNTING
Lombardini LGA 340
C-CHANNELS WITH HOLES ENGINE MOUNTING
BOLTING FINALISING
DFMEA
INNOVATION
HYDRAULICALLY & COIL SPRING OPERATED VARIABLE
SUSPENSION SYSTEM
OIL TANK
OIL PUMP
OIL PUMP
OIL TANK
OIL CYLINDER
OIL CYLINDER
NORMAL MODE
OPERATIVE MODE
IT PROVIDES OVERALL VARIABLE STIFFNESS TO THE
SUSPENSION SYSTEM.
HELP TO INCREASE/DECREASE GROUND CLEARANCE.
EASES THE DRIVER WHILE DRIVING AROUND A RADIUS.
DESIGN VALIDATION PLAN
RELIABLE
AND SAFE
SR.NO.
COMPONENT PROPERTY TEST VALIDATION
1. Chassis welding Destructive
testing
Comparing the stress level
obtained with permissible level
for the given material.
Dimensions Measuring
Manually
Rechecking and comparing
with 3-D model
2. Brakes Pedal Position Trials to be
carried out
Suitable for both of our
drivers.
Brake force Trial on
vehicle
Safe and short stopping
distance.
3. Steering Wheel
position
Trial on
vehicle
Comfort to the driver
Maneuverability
Static test Degrees of turn of tires per
degree of rotation of wheel.
4. Transmission Engine
mounting
Test for
Vibration
Centre position & less
vibration.
Axle length Trial Compare with standard
assembly.
PROJECT PLAN
SR NO. TASK DEADLINE
1 STUDY OF RULEBOOK 2
ND
Week of January
2 DATA COLLECTION 15 th Feb
INITIAL DESIGN 28
th
April
3 3-D MODELING 15
th
May
4 PDR 26
th
May
5 ANALYSIS 30
th
July
6 COST ESTIMATION 20
th
August
7 FINAL DESIGN 30
th
August
8 MARKET SURVEY 30
th
August
9 SPONSORSHIP 25
th
September
10 MATERIAL PROCUREMENT 20
th
October
11 FABRICATION AND ASSEMBLY 10
th
December
12 TESTING 10
th
January
13 FINAL DESIGN REPORT 20
th
January
CHASIS
TRANSMISION
STEERING SUSPENSION
BRAKES
RELIABLE
AND SAFE
1. Ghorpade Abhijeet
2 Vivek Mahajan
3.Thombare Sagar
4. Ashish Rajoba
5. Siddhesh Yadav
1. Swapnil Babar
2. Ajay Borate
3. Akshay Rukhade
4. Rahul patil
5. Nityanand Khushwaha
6. Hariom
1. Shahnawaz Tambe
2. Mahesh Kale
3. Katti Indrajeet
4. Aniket Patil
5. Thorwat Aniruddha

1. Saddam Hussain
2. Indranil Banerjee
3. Abhineet Badve
4. Ashish Patil
TEAM STRUCTURE AND
DISTRIBUTION
1. Saddam Hussain
(captain)
2. Pranav Kawre
3. Pankaj Salgare
4. Kulkarni nilesh
5. Chetan Bhupal

COLLEGE FACILITIES
-HIGHLY EQUIPPED WORKSHOP
- CNC Machines
-Drilling Machines
- Milling Machines
- Lathes
- Sheet Metal Bending Machine
- Arc Welding
- Smithy shop
- UTM
- CAD Lab-ADVANCED HOYT TRAINING LAB
- LIBRARY- Books and Journals on Automobile.
- INTERNET + 24 hr Wi-fi
- SEPARATE SPACE FOR SAE BAJA VEHICLE
FABRICATION.

SAFETY
PRECAUTIONS TAKEN :
A five point restraint harness
Single metaltometal quick release lever type
buckle
Engine Shield.
Seat Belts as per the rule of SAE
Avoid breaks in the Design of Roll- cage.
Helmets and fire-proof suite.
Fuel spill-drip pan.
Fire-resistant roll- cage padding.
Separate master cylinders for braking system.
Avoid or remove sharp edges or burrs.