IIT JODHPUR

Comparative Analysis
   Parameter Old vehicle New vehicle Parameter Old Vehicle New Vehicle
Length​ 77’’ 77” Maximum 7.355 KW (10
7.355 KW (10 HP)
Width​ 58”  56'' Power HP)
56”​ Maximum
Height​ 55.8” Torque 19.66 N-m 19.66 N-m
Wheelbase​ 57” 55'' CVT (CVTech),
Track Width 52” ratio 0.43:1 to CVT (CVTech),
50''
(front)​ 3:1 ratio 0.43:1 to
Track Width (rear)​ 46” 48'' Transmission Custom 3.0:1

Performance specifications
Gearbox, Custom Gearbox,
Design ​ Ground Clearance​ 11”  12''
Reduction Reduction 8.89:1
Kerb Weight​ 161 kg 150 kg
11.6:1
Weight 46.0 : 54.0  (F:R)​  42.0 : 58.0 (F:R) Maximum
Acceleration 6.8 m/s 5.37 m/s2
2
Distribution​
17.01” (height) 17.87” (height) Top Speed 54.9 kmph 56 kmph
Technical Specifications

COG Coordinates​ 30.75”( front axle) 31.9”( front axle) Gradeability 64.90% 64.9%
26.25”(rear axle)​ 23.1”(rear axle)​ 
22”x8”-10” Front; 22”x8”-10” Front;
Tyre Size​ 22”x8”-10” Rear​​ 22”x8”-10” Rear​​ 
Independent,
Front Suspension​ Double Wishbone Independent,
Double Wishbone​
Power to
Suspension Rear Suspension​ Independent, Independent, Weight Ratio 32.42 W/kg 33.89 W/kg
& Steering ​ H – Frame Lower​ H – Frame Lower
Steering Type​ Rack & Pinion​ Rack & Pinion Comparison
Turning Radius​ 106.30” (2.7m) 94.49"(2.4 m)​
Front​ Disc Brakes ​ Disc Brakes ​
Braking​
Rear​ Disc Brakes​ Disc Brakes​

BAJA 2017 BAJA 2018

Roll cage Design Process - Ergonomics
Design constraints| Application |Weight |Manufacturability |Safety |Aesthetics |Cost
DESIGN PROCESS
Background research
Ideation
Brain storming
Detailed Design
Testing
Validation
Design Review
• Benchmarking
• Drawbacks in previous
vehicle
• Rulebook constraints
• Ergonomics
• Sketching and
conceptualisation
• Inputs from
subsystems
• Design inputs from
analysis team
• Development of roll
cage
• Design iterations
• Optimised diagonal members
• Better orientation for suspension
mounting
• Flexible roll cage for better
handling and weight transfer
ERGONOMICS
• Custom made seat and steering
wheel
• Leg space and comfort ensured
using simulation software
• Steering wheel at comfortable
position
• Placement of Driver controls
• RRH inclined at 6 degrees
• SAE Standards
• Inputs from • Material selection
subsystems • CAD model with
• Design iteration different tube
• Common CAD model dimensions
• Design release • FEA & optimisation
• Detailing from • Aesthetics
Manufacturing POV • Final assembly
CAE Basic Processes and its Applications
DESIGN PROCESS CES Edupack and Benchmarking • Driver tolerance levels
• Weldability • Chest acceleration & Femur load
Literature • Strength and stiffness • Benchmarked pulse models
• Carbon Content • Safe stopping distance
Material Selection
• Work energy principle
Mesh method & size • Crumple zone
Boundary conditions Material OD Thickness Bending Bending Weight Yield
(in) (mm) strength stiffness /meter Strength
Force values (Nm) (Nmm^2) (Mpa)
Design modifications AISI 4130 1.25 1.65 485.402 3631.45 1.22 435
AISI 1018 1 1 164.44 1170.824 0.59 365
AISI 1018 1 1.6 244.420 1743.422 0.92 365

Torsional stiffness in N-m/deg

• Conventional 980

Roll Over Side Impact Rear Impact Front Impact

5G, FOS 1.69 3.5G, FOS 1.98 6.5G, FOS 1.46 6.5G, FOS 2.57
Suspension Design – Front / Rear
DESIGN PROCESS • Reduce wheel assembly size using stub axle and stub knuckle
• Better weight transfer during cornering
Literature &
Benchmarking
Cog , Mass Transfer
calculations

Defining Constraints

Iteration of hard
points in Lotus

Geometry Design Front : Double

Wishbone Unsprung mass :
55.6 kg
Structural Analysis Rear : H – Frame
Lower Castor 10 deg
KPI 8 deg
Roll Gradient :
4.3 deg/g Scrub 0 cm
Radius

Specifica Wheel Roll Camber Toe Roll Stiffness Spring Motion Natural Ride Rate
tions Travel Centre Change Change (kg-m/deg) Stiffness Ratio Frequency(Hz) (N/mm)
(N/mm)
Front 6 (Bump) 2in 4 (Bump) -2 109.2834 11.21 0.7 1.56 7.24
4(Droop)
Rear 5(Bump) 0 7 (Bump) 0 149.7987 18.8 0.7 1.43 12.36
3(Droop)
Braking
Material Thermal Stress Weight
Selection
Solid Disk
Analysis
Venting
Analysis Reduction Brake calculations
Weight Transfer % 56.8
DESIGN PROCESS
Force Distribution 68:32
Literature, Benchmarking
Friction Coefficient B/w Tyre  &  Road
Force distribution, Calculations = 0.7
B/w pad & disc =
Brake Circuit Design 0.45
Thermal
Parameter estimation Torque Required Front = 166 N-m
Brake disc Rear = 75 N-m
Rotor and Pedal: Design and
Material G. Cast Iron
Analysis Force Required by Front = 1137/2 N
Max Temp 310 Caliper Rear = 512 N

Min. Temp 158 Master Cylinder 2.3 Mpa

Pressure
Braking Specifications
Disc Diameter Front  = 170 mm
FEA Split type F/R Rear = 200 mm
Brake pedal properties Brake Bosch Tandem
Master Stroke- 25.4mm
Material Aluminium cylinder Bore Diameter-
19.05mm Brake calculations
Applied Load 300 N Stopping Distance 8.8+9.1=17.9m
Brake type Disc Brake
Max. Stress 223.1 Mpa Brake Apache RTR 180 Stopping Time 0.8+1.6=2.4
calliper
Max Deformation 1.23 mm Pedal Specification Ratio=4.5:1
Brake pad Semi-metallic Apache Travel=127 mm
FOS 1.89 RTR 180 Force = 150 N
Brake fluid DOT4
Steering & Wheel Geometry
Specifications
DESIGN PROCESS Turning Radius 2.
(metres)
Literature & Benchmarking
FRONT: Motor cross ATV Tire
Fixation of Wheel base, track width • Extended surface and tread Rack Travel(cm) 7
pattern
Rack travel and steering arm length Pinion dia. 26.6
• Ideal for all terrain types
(mm)
Steering force calculation • Specialised tread compound
improves traction
Steering Ratio 122.76
Under steer -0.00285
Gradient (over steer)
REAR: Mud ATV tires
• Angled knobs dig into Steering angle Inner -45.00
terrain for maximum (degrees) Outer-28.3
traction.
Steering 8.24
• Use under a wide range of Torque(Nm)
conditions.
Ackermann 50%
Percent (%)
FRONT REAR
Steering 30
Wheel Tubeless tires column
geometry Angle(degree)
Front tire 21.5*7.2-10
Steering Wheel 5/6 turns lock
to lock
Rear tire 22*8-10 Detachable
steering wheel
Power Train
Design
Design constraints|
constraints| Application
Application |Weight
|Weight |Manufacturability
|Manufacturability |Safety
|Safety |Aesthetics
|Aesthetics |Cost
|Cost

DESIGN PROCESS Vehicle Performance

Literature study and Benchmarking Acceleration 5.37 m2/s
Deciding vehicle parameters Grade-ability 64.9%

CVT selection Top Speed 56 Kmph

Power to Weight 33.89 W/Kg
Calculation
Gearbox design
Validation ENGINE

Design Review Max. Power 10 HP at 3600

Max. Torque 19.66Nm at

2800rpm

• Flat assembly Transmission Type

• Use of DAQ system to tune the CVT. Constant Velocity CV-Tech CVT
• Use of a exhaust manifold Transmission (Gear ratio
• Optimized gear ratio as compared to last (CVT) 0.43:1 to
year 3.0:1)
• Use of modified Half-shaft.
• Usage of Cylindrical dampers Coupled with a Gear Ratio
single gear 8.89:1
• Use of custom gearbox reduction custom
• No differential used to overcome gearbox
shortcomings of open differential
 DFMEA
SUBSYSTEM COMPONENT PFM S EFFECT OF FAILURE O POTENTIAL CAUSES OF FAILURE D RECOMMENDED RPN VALIDATION
ACTION
Frame Rollcage Deform 6 Structure damage 6 Excessive load, improper manufacturing 4 Replacer deformed 144 FEA of forces impacting
member
  Mountings Deform 7 Failure in functioning 7 Improper manufacturing, Excessive loading 5 Replace 245 Static FEA
of attached
components
Steering Tie Rod Bend 7 Permanent changed 5 Excessive stress experienced 6 Replace 210 Bump Steer, end play test
toe angle
  Heim Joint Break 10 Steering control is lost 6 Excessive loading, improper manufacturing, 6 Replace 360 Pre-run tests
Jerk due to larger bump

Suspension Arms Bend 7 Tyre misalignment 4 Excessive load due to Bump, Welding 5 Repair 140 Bump Test and FEA
deformation, improper manufacturing
  Bushings Deforma 5 Restriction of motion 7 Uneven dynamic load distribution, Bad 4 Replace 140 Track runs on rough
tion quality terrains
Wheel Hub Hub Axial 10 Wheel instability 3 Absence of proper fitting with knuckle/ 10 Restraining knuckle 300 FEA of forces/ conditions
assembly moveme improper manufacturing of hub and hub properly/ after test runs
nt/Break Replace
  Knuckle Break 8 Change in tyre 5 Improper Designing, excessive loading 8 Replace 320 FEA of forces acting
alignment, Dynamic
unstability
Transmission CV-axle Damaged 8 Vehicle failure 6 Excessive load 7 Welding/Replacing 336 FEA of CV axle
axle CV axle
  Gear Box Worn out 6 Hampered Vehicle 4 Manufacturing defect 10 Replace Gears 240 Dry Run Test
performance
Braking Brake disc Wearing 7 Degraded breaking 5 Manufacturing defect, insufficient 7 Replace 245 Break Dynamic test
of disc, force resistance of material to indentation
cracks
  Caliper Deform   Wearing of disc   Improper design, Manufacturing defect   Replace the mount   FEA of forces acting
mount(Rear) brakes, engine
efficiency reduced
Engine Air Filter Blocked 7 Absence of air in 5 Filter getting jammed by dirt/mud 6 Clean/Replace 210 Check after run
filter engine
  Piston Piston 8 Inability to start the 2 Engine oil runs out 9 Engine Servicing 144 Engine testing: Start/Stop
Cylinder Seizure engine cycle
Electrical Electrical Cut, 8 Failure in functioning 6 Sudden axial stress or shear force 8 Rejoin the wires if 384 Circuit testing
wires Short of electrical experienced broken/ Replace
circuiting components
 14
Team Composition with work allocation,College Manufacturing Facilities
Faculty Captain Vice- Vice- Marketing Design & FEA Suspension & Braking Power Train Materials and
advisor Captain Capatin Steering Manufacturing
• Overlook Distributing Overlook Paper Approach Rollcage , Suspension Brake Ckt CVT Performing
team work financial work potential wheel geometry design selection material
Deciding issues Ensuring companies assembly , Shocker Brake disc Gearbox selection
functioning timelines and Financial deadlines willing to Suspension selection manufacturing design, process
• Final ensuring they planning are being sponsor arms design Steering Pedal manufacture Overlooks
design are being and followed project in FEA and Geometry manufacturing Engine special
Approval followed budget Take part or in optimization Wheel selection mount manufacturing
Solver in case of making regular cash design and of certain parts
conflicts Banking feedback Powertrain
Design sub team and record s assembly
keeping

Dr. Karthik Krishna Sanket Divyanshu Poojan Vivek Singh Ritwik Sharan Aniket,
Kaushal Mohan Goyal Nakka ,Gautam, Pranav Somesh, Ankit Nitish , Parth Joshi,
Desai Sachin Preshit Mukul Mukesh Ashutosh Sudhir
Dr. Pravsh Saini Nitesh Rai Vishal Jain Shubham
Anand
Plapally

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