ST.

MARTIN’S ENGINEERING
DepartmentCOLLEGE
of Mechanical Engineering
Major Project External VIVA
TOPIC: DESIGN and fabrication OF THE BUGGY CAR

Presenting By:
J. Sai Krishna : P. Mahesh kumar : 17K85A0324
16K81A03D6 S. Bharath : 17K85A0314
K. Charan Kumar : N. Goutham :
16K81A03C8 16K81A0327
Praveen Choudhary : N. Nikhitha Reddy : 16K81A03A0
16K81A03D3 B. P. Abhilash : 16K81A03A3
Prashanth : 16K81A0365
D. Rahul raj Guide:
: Dr. D.V Sreekanth
17K85A0321
 Design Methodology
Analytical The forces, stresses and any other parameters related to the design
are calculated or assumed based on the problem
Calculations
The material for the component is selected based on the application,
Material cost ,weight or any other parameters etc.
Selection
The design of the vehicle parts are done by using various methods and
CAD Design of softwares. The CAD softwares like Solidworks, CATIA are used to
the component design the CAD models of the parts of the vehicle.
The parts after the completion of the design are analyzed using Finite
CAE analysis of Element Method by using various CAE softwares like ANSYS and
the components Hyperworks.

Lotus software is used for the Dynamic simulation of the suspension

Simulation system to obtain mounting points.

The parts are optimized based on the results obtained from the CAE
Optimization softwares and other simulation softwares to improve efficiency of
design and reduce the weight of the component etc.
 Design and CAE of Roll Cage
Rollcage is the structure which holds all
the components.
We have used AISI 4130 material pipes
for the fabrication of the rollcage.
The rollcage consists of two members –
• Primary members – 29.2mm x 1.65
mm
• Secondary members-25.4 mmx1.65
mm

Side Impact Roll Over Impact

Boundary Conditions Results

Max Max FOS
Max Max Impact stress Deformati
S.no Details (MPa) on
Force(N) Force time (mm)

1 Front 13500 4.5 G 0.2 s 360 0.28 1.28

impact
2 Side Impact 6000 2G 0.2 s 427 0.85 1.2

3 Roll Over 9000 3G 0.2 s 212 0.47 6.8

Impact
4 Rear 6000 2G 0.2 s 354 0.31 1.3
Impact
Front impact Rear Impact
 Fabrication of Rollcage
Welding TIG Welding
Filler Material MS-ER70S-1.65 mm dia
Manufacturing Cutting, Grinding, Bending(
processes CNC & manual),Welding
 STEERING
Steering System Parameters
Steering type Rack and Pinion

Lock to lock Turn 588°

Rack travel 126 mm

Steering ratio 7:1

Tie rod length 310 mm

Steering
Steering arm length 150 mm

Steering column collapsible

Steering wheel dia ɸ300mm

Steering Geometry
Ackerman angle 25°
Inner steering angle 42°

Outer steering angle 26°

Ackerman% 65 %
Rack and Pinion Turning radius(wrt C.G) 2374 mm Ackerman Layout
 SUSPENSION
SUSPENSION
Suspension Geometry
Wheel base 1460 mm

Track width (front) 1350mm

Camber -2°

Caster +8°

SAI +8°

Scrub Radius +50 mm

2D Wheel Geometry Toe in Adjustable

Type of Suspension
Double Wishbone
Front Rear
A- Arm H –Arm
Fox Float-3 Endurance
Material AISI 4130
 BRAKING
BRAKING CIRCUIT
Type of circuit X - Split Circuit
Front Rear
Type of brake Outboard Outboard
Disc Brake Disc Brake
Master Cylinder ɸ19.05 mm
Brake disc ɸ160 mm ɸ180 mm
Brake calliper ɸ30 mm ɸ30 mm
cylinder
Brake calliper 25 mm 25 mm
pad
Brake fluid Dot 3 Pedal Braking Layout

BRAKING PERFORMANCE
Pedal ratio 6:1

Pedal effort 200 N

Deceleration rate 7.85 m/s2

Stopping distance 8.14 m

Caliper Layout Disc Brake

Brake Bleeding
The process is performed by forcing clean, bubble-free brake fluid
through the entire system, usually from the master cylinder to the
calipers of disc brake ( but in certain cases in the opposite direction). A
brake bleed screw is normally mounted at the highest point on each
cylinder or caliper.

Procedure of Brake Bleeding

Locate the bleed screw

Connect the bleed screw with pipe and an

empty jar

Push and hold the pedal

Remove the bubles and bleed the brakes

Check the master cylinder

Tight the screw

 TRANSMISSION
S. No Drivetrain Parameters Specifications

1 Transmission CvTech CVT, Reduction Gear

Box, Spool type
2 Final Drive Type 2 stage reduction gear box

3 Final Drive Ratio 10:1

5 Theoretical Top Speed 60 KMPH,64 KMPH

6 Starting CVT Ratio 3:1

7 Final CVT Ratio 0.43:1
8 Half shaft size and Tata Nano Shafts -30 mm dia
material
9 Joint type C.V Joint Engine Mounting
11 Acceleration time 100’ 3.6
12 Maximum grade 38֯֯
capability

Engine Specifications
Manufacturer Briggs and stratton
Power output 10 hp
Displacement 305 cc
Maximum Torque 18.98 n-m @ 2700 RPM
Engine type Single Cylinder , 4-stroke

CVTech CVT CAD Model of Gear Box

 CFD AND THERMAL ANALYSIS OF DISC BRAKE

Surface Heat Transfer

Temperature – 91 ֯ C Wall Heat Flux Distribution Factor of Safety- 2.35
Coefficient – 357 W/m2-K

Total Deformation- 0.05 mm Velocity of air around the disc Stress Developed – 216 MPa Thermal Strain – 0.008 mm/mm

Paper Publication in International Research Journal of Engineering and Technology (IRJET), Vol 7,Issue 5
 CAE analysis of Suspension Components

Lower A Arm H Arm Rear Knuckle Rear Hub

Boundary Conditions Results

Max Max FOS
Max Max stress Deformatio
S.no Details (MPa) n
Force(N) Force (mm)

1 Front 900 3G 225 0.28 1.28

Knuckle
2 Rear 900 3G 237 0.01 1.2
Knuckle
3 Front Hub 900 3G 264 0.1 1.48
4 Rear Hub 900 3G 384 0.17 1.3
5 A Arm 600 2G 194 0.17 1.82
Front Knuckle Front Hub 6 H Arm 600 2G 187 0.2 1.5
 WHEEL ASSEMBLY

Front Hub Front Knuckle Wheel Parts

S.NO Part Name Material Machining
Process
1 Front Hub Aluminium Vertical
2 Front Knuckle M.S Milling
Cutting
3 Rear Hub M.S Process
4 Rear Knuckle Aluminium (VMC)

Tyre Dimensions :

Front Tyre : 23” x 8” - 12”

Rear Hub Rear Knuckle Rear Tyre : 23” x 8” -12”
 Overall Vehicle Details
FRONT TRACK
WIDTH= 1350 mm

HEIGHT
TOTAL LENGTH = 1193 mm
= 1960 mm

WHEEL BASE=
1460 mm
REAR TRACK WIDTH GROUND CLEARANCE= 304 mm
= 1300 mm

Overall Performance Details:

Weight:
Maximum Speed (KMPH) : 58kmph
Kerb Weight :215 KG
Maximum Acceleration : 7.19m/s2
FAW to RAW Ratio : 2:3
Gradiability (%) : 44 % ( 24֯ )
Laden Weight : 270 KG
Stopping Distance : 7.86 m
 DESIGN FAILURE MODE AND EFFECTS ANALYSIS
PART Faliure cause PRECAUTIONS Severity Occurrence Damage(D) RPN
(S) (O) (S*O*D)

ROLLCAGE Excessive load leading Using high strength material 5 2 3 30

to excess bending stress
Leakage in fuel tank Regular check of fuel tank 6 2 4 48
ENGINE

Car Cornering Effect Toe in Is Adjustable with Tie

during Braking rod ends 5 3 3 45
STEERING
Hard steering Castor angle = 6 degrees 4 2 3 24

Circuit failure due to Checking before every run 5 2 3 30

leakage
BRAKING
break pad wear Checking before every run 5 1 2 10

Failure of front lower A Annealing steel tube before 7 1 7 49

-arm welding
Excessive load leading wheel travel is kept higher than 4 3 3 36
SUSPENSION to high bending moment ground clearance
at suspension mounting
points.
 DESIGN VALIDATION & TESTING
PART NAME OF Test method
THE TEST
ROLLCAGE Welding Test Check the welding strength of the roll
cage by dropping from considerable
height.
DIMENSIONS Compare the designed dimensions of
TEST the roll cage with the fabricated roll
cage.
BRAKES Bleeding Continuously pressing the pedal &
Test check for any leakage.
Stopping Apply the brakes when the vehicle is at
distance test maximum speed and check the stopping
distance of the vehicle.
STEERING Maneuverab Drive the vehicle in curve paths and
ility test uneven surfaces.

TRANSMISSION Vibration Check for the vibrations and noise from

Test the engine.

SUSPENSIO Suspension Check the suspension ability to

Test withstand loads on bumps on
suspension track.
Questions ???

Thank You !!!