1

Acropolis Technical Campus

Indore (M.P)
TEAM ID : 15128
ACRO-IGNITERS

Old Team ID Car No. Endurance Score Total Score Award

70874 02 - -
Qualified
acroigniters15@gmail.com
 SAE INDIA BAJA
Rule Book 2015 Highlights
2
S.NO Section no Page no
Rules
1
3” clearance of driver from every member of roll cage B 7.2 20

2 The driver’s helmet shall have 6” clearance to the side surface B 7.2 20

3 Cockpit must designed to 1)- Protect the driver B 8.1 28

SAFETY

2)- Permit easy driver exit in an emergency

4 All rotating parts must be shielded to prevent injury to the driver B 13.1 40

5 Each vehicle must be equipped with two easily accessible KILL switches for turning off B 3.3 14
ignition
6 Spill prevention B 11.6 37

7 Vehicle speed must not exceed 60 Kph B 2.7 13

TECHNICAL

8 Governor setting not to be exceed 3800 rpm B 2.5.14 12

9 The brake must be capable of locking ALL FOUR wheels B 10.1 35

10 The vehicle must be capable of carrying one persons 190 cm tall & 113 Kg weight B 1.1.1 9
 Vehicle Technical Specification 3
Particulars 0ld 2013 Proposed Old 2013 Proposed 2015
2015
Brakes
Overall Weight (Kg) 380 323
(With driver) Type 4 Wheel Disc 4 Wheel Disc

Disc Size (Front/Rear) 190/190 220/200

Kerb Weight (Kg) 267 210
(mm)
Overall Vehicle 90*60*60 76.5*60*55
Dimension (L*B*H) Split Type Front-Rear Front-Rear
(inch) Suspension
Type (Front/ Rear) SLA coil-over damper / SLA SLA with coil-over damper./ 3-
coil-over damper Link trailing arm with air shocks
Vehicle Geometry (Inch)

Wheel Base 70 57 Steering

Wheel Track 52 52 Steering Rack & Pinion 18 11

(Inch)

CG Height 19 18 Transmission

Ground Clearance 9 10 Drive Type Chain Drive Chain Drive

Wheel Size (Inch) 25*8*12 23*8*12

 Vehicle Performance
4
Engine And Transmission Previous New

Acceleration m/s2 1.26 1.55

Maximum Speed (Kph) 56 53

Grade-ability (degree) 31 38

Tractive Force (N) 1988 2058.46

Previous Design Draft

Brakes And Suspension Previous New
Deceleration 0.7g 0.7g
Stopping Distance (m) 17.2 16.2
Suspension Travel(Front/Rear) 114.28/130 208\220
(mm)

Steering Previous New

Turning Circle Radius (m) 2.7 2.32

Conclusion – More the tractive force, better the acceleration.

New Design Draft
 Previous Design Baja vehicle 2D-3D Proposed Design 5
Front Side

55”

52” 52” 57”

Isometric

Top

INFERENCE: Dimensions reduced from previous design for better performance.

 Ergonomics Design
6
Design Methodology
1. Concept
2. Standardize New Frame
45˚ 3. Verification
4. Built and test
3” 3” 5. Changes and
110˚ implementation

30˚ 110˚ Design Consideration

70˚ 1. Structural rigidity
2. Drivers safety
Material Comparison 3. Integrity of drive
S.No Parameters AISI 1018 AISI 4130 line and suspension
1 Carbon % 0.18 0.30
2
3
Yield strength (MPa)
Ultimate strength (MPa)
370
460
435
670
Driver’s view Old Frame
4 Chromium % - 0.8 – 1.1
5 Cost Rs/ft. 140 448

S.No Parameters Pervious Design Proposed Design

1 Dimension (inch) 85x35x50 70x30x45
2 Material AISI 1018 AISI 1018
3 Section OD (inch) 1 1
4 Weight (Kg) 70 49.2
 Finite Element Analysis
Front Impact Test Rear Impact Test Side Impact Test
7

Max Stress Deformation Max Stress Deformation Max Stress Deformation

FEA Consideration: Shear Stress Theory Of Failure

2.0860348424198
S. Load Test Loading condition Load Stress Defor FOS
No (N) Results mation F.O.S Comparison

2.20114833
previous design V/S new

1.45497443963822
1.42356969720287
(σ) MPa mm

1.34082261279217
1 Front Impact Collision at max velocity 23520 259.91 2.17 1.42 design

2
2 Rear Impact Collision at avg .velocity 9004 254.3 2.76 1.45

1.4

1.4
1.4
3 Side Impact Collision at avg. velocity 9004 275.95 4.9 1.34
4 Drop Max velocity limited as √2gh 6950.6 206.23 0.5 1.79
5 Roof Crush Max load 3mg, as per SAE J374 7350 168.089 1.91 2.20
6 Torsion Vehicle over a bump. 2854 177.37 1.9 2.08
f r ont i m pact Rear i m pact S i de i m pact Roo f cr ash t o r si on t est
7 Bump Vehicle into the bump 2858.9 194.73 3.02 1.9 t est

8 Lateral Bending Vehicle at cornering 4939.2 200.13 1.09 1.84 previous vehicle new design
 Finite Element Analysis
Total Deformation
8
1) Lateral Bending 2) Torsion Test 3) Drop Test 4) Bump Test 5) Roll Over Test

Problems Encountered Previous Design Proposed Design

1) Placement of transmission box

2)
Heavy roll cage affecting vehicle
performance
Lesson Learnt
1) Design for manufacture
2) Optimization in roll-cage design

Improvements Planned
1) Design modification at rear end
2) Structure design with minimum
members and maximum strength
 Suspension Design
Lesson Learnt
9
Design Consideration Basic Calculation
1. Long suspension travel 1. To ensure braking & maneuver performance Variables (Front) Values
2. Maximum traction during all adequate traction is required
driving condition 2. Appropriate degree of damping results in Spring Coil Dia. (mm) 10.62
3. Adequate camber change
eliminating road irregularities Mean Coil Dia. (mm) 84.96
Previous (Rear Geometry) Proposed (Rear Geometry)
Free Length (mm) 294.65
3 LINK TRAILLING ARM
WITH FOX SUSPENSION No. Of Active Coil 12
Pitch (mm) 22.66
Stiffness (N/mm) 17.46
Suspension Travel (mm) 208
Spring Index 8
Previous (Front Geometry) Proposed (Front Geometry) Damping Coefficient 0.942
(Ns/mm)
Geometry Double wish bone A-arm

Variables (Rear) Values

Pressure Range 25 to 300 psi

Weight 2.1 lbs at 14.1”
 Wheel Geometry
Front suspension geometry
10
Parameter Values /Material
Camber (-2̊)
Caster (+4̊) Wheel size (front & rear) 23*8*12
SAI (10̊) 12”
Rim OD
Rim wall offset 5”
Knuckle (Custom made) Aluminum Alloy

Hub (Custom made) Mild steel

Improvement Rear knuckle Front knuckle
1. Ensuring traction in all driving
condition by providing

Previous
appropriate stiffness to spring
2. Increasing the roll center height
from ground which will reduce
rolling HUB Total Deformation

Conclusion:

New design
1. Simplified rear geometry
2. Reduces rolling & pitching
3. Reduce unsprung mass
4. Straight line stability
 Steering
Design Consideration 11
1) Quick response to less operating force Principle Variables Old New
2) Reducing Ackermann’s error Type Centrally aligned Centrally aligned
3) Effective turning radius
Ackermann’s steering geometry
rack & pinion rack & pinion
4) To Improve corning ability of the
vehicle
Steering rake 18 11
5) Minimize bump steer
Proposed Design (inch)
11” Rack And Pinion
Steering Ratio 18:1 12:1

No. of turns(lock 4.1 2.7

to lock)

Turning radius(m) 2.7 2.32

Turning 40 41
Lesson Learnt angle(Inner) deg.
1) Tie rod inclination should be Improvement
appropriate
Turning 25 25.8
2) Steering ratio should be
1) Improved steering ratio angle(Outer) deg.
minimum
3) Absolute wheel lock to lock 2) Reduced turning radius
4) To design Ergonomically Tie rod ( inch) 14 16.5
 Steering 12
Innovation In Steering
Ackermann’s  Aim: “Study of ergonomic design and technological improvement
Geometry of steering system by using steering quickener”

CONCEPT :
 Change the steering ratio by using 3 gear arrangement
N1/N3=T3/T1
ADVANTAGE :
 Variation of steering ratio could be done in any type of vehicle using
1.07” this type arrangement
 No alternation in rack an pinion arrangement
 Reduces drivers steering effort in mechanical rack and pinion system
COMPONENTS :
1) Gears
2) Steering box
3) Steering column
4) Frame structure
 Brake Design
13
Parameter Calculated Value
Design Consideration
1) All four wheel should lock simultaneously at maximum speed
2) Optimum weight transfer
Applied Braking Torque 450.12 Nm
(Front axle)
Applied 288.73 Nm
Lesson Learnt Braking Torque (Rear axle)
Appropriate brake ratio results in increased braking performance
Required Braking Torque 379.889 Nm
(Font axle)

129.2 Kg
450.12(F)/288.73(R) Required Braking Torque 234.07 Nm
Nm 193.8 Kg (Rear axle)
Braking Torque
Pedal ratio 6:1

34.2”
Pedal force 300N
C.G
Stopping distance 16.2m
F R
18”

Stopping time 2.14sec

16.2 m stopping distance 70 Kg Weight transfer Master cylinder pressure 5.263MPa

Weight Transfer 70 Kg
 Brake Design
14
Brake Geometry Specification Design Parameter Values
Brake Type 4 Wheel Disc Brake
Static load at front axle (kg) 129.2
Split Type Front & Rear
Static load at rear axle (kg) 193.8
Disc Size Front (mm) Bajaj 220
Total weight of the vehicle (Target) 323
Disc Size Rear (mm) Bajaj 200
(kg)
Master Cylinder area(mm2) 285.02 Dynamic load @ front axle 1942.38
(Braking) (N)

Dynamic load @ rear ( Braking ) 1196.82

(N)
Height of C.G form ground (inch) 18
Distance of C.G from rear axle 22.8
(inch)
Distance of C.G from front axle 34.2
(inch)
Rolling radius (inch) 11.5

Brake Assembly Coefficient of friction between road 0.7

and wheels
 Transmission
Design Consideration
Basic Calculation 15
1) Desired gear ratio to achieve Parameters Old New
target speed of 60 kmph
Principle Gear box Mahindra alpha Mahindra alpha
2) Compactness and weight (4+1) 4+1
Transmissio Forward/rear Forward/rear
Propagation of power from
Problem Encountered n orientation engine/rear wheel engine/rear wheel
1) Mounting of gear box below oil smaller gear to higher gear
filling neck Coupling Chain drive Chain drive
type
Max Speed 56 kph 53 kph

Previous Design Proposed Design Time 0 to 56 kph in 0 to 53 kph in

12.34 sec 9.81 sec
Max 4.2 6.27
Acceleration
m/sec2
Max 1988 N @3600rpm 2058.46 N @
Tractive 3600rpm
force (N
Grad-ability 31 38.8
(Degree)
-VE Inclination Wheel Size 25*8*12 23*8*12
(Inch)
Horizontal Line
 Transmission
16
Tractive Force (N) V/S Gear Velocity (kph) V/S
1800 Grade-ability in degree V/S
1600
45 Gear Gear
1400 60
Tractive Force

40

Grad - ability
1200 35 50
1000 30

velocity
800 25 40
600 20 30
400 15
200 10 20
0 5 10
1 2 3 4 0
-5 1 2 3 4 0
1 2 3 4
Gear
Gear
Gear
Improvement
Gear Ratio
Lesson Learnt 1) Appropriate inclination of gear box for oil flow
1) Alignment of gear box 1 st
31.45:1 2) Smoothness in gear shifting
2) Chain tightening should be proper Gear Speed (Kph)
3) Mounting and removal of gear box 2nd 18.70:1
should be easy 1st 12
3rd 11.40:1
2nd 21.04
Conclusion : Improves Grade- 4th 7.35:1 3rd 34.53
ability
rev 55.13:1 4th 53
 Previous Vehicle Proposed Vehicle
seat
3%
ABC lining
2% battery engine
Total weight 380 Kg Total weight 323 Kg
Battery
17
Seat ABC Lining
steering 2% 12% 1%
1% 2% Drive Line
3%
Transmission 2%
suspension 8% Steering
Disc And Calliper
6% 4%
4%
Suspension Engine
3% 13%
A-arms Transmission
Trailing Arm 8%
3%
2%
rollcage A-arms
hub and knuckle wheel and rim 29% Roll Cage
12% 20% 3% Wheel And Rim 22%
Hub And Knuckle 22%
9%

Body Panel Fastners Total Cost Total Cost Welding

1%
Welding 1% Break ABC Lining
Assembly Rs2,85,580 Rs3,10,000 3% Body Panel
9% 1% 1% ABC Lining
3% Helmet Break Assembly
Helmet Roll Cage Pipe 3% 1%
Fastners 6%
3% 8% Suspension 1%
Driver Suit 3% Driver Suit Roll Cage Pipe
4% 3% 4%
Transmission
Suspension
Fire Extenguisher 8%
Fire Extenguisher 18%
1% Steering
Tail & Head Light 1%
6%
2% Tail & Head Light Steering
Battery 5%
Engine 2% Battery
2% Tyres
18% Hub and Knuckle 1%
Tyre And Rim 15%
Hub And Knuckle 26%
27%
5%
 Project Plan And Design Verification Plan 18
Design Verification Plan
Test Plan
Test Id Test Method Task Discriprtion Acceptence Criteria Test Stage
T1 Roll Cage
Max Shear Stress Design
T1.1 Impact Testing FEA
Theory Verification
T2 Engine
T2.1 Engine Idling (12hrs) Cold Start RPM Trial Run
T3 Suspension
Suspension Design
T3.1 Uneven Terrain Motion Ratio
Travel Verification
T4 Transmission
Design
T4.1 Idling Condition Torqueing Gear Ratio
Verification
To Meet
T4.2 100 ft Track Max Speed Trial Run
Specification
T5 Steering
Turning Circle To Meet
T5.1 Figure Of 8 Trial run
Radii Specification
T6 Electricals
Battry
Vehicle T6.1 Electricals
Installation
Voltage  
Dynamic
T6.2 Iinstruments Clusters Speedometer Speed  
Testing
To Meet
T6.3 Switches & Control Switches  
Specification
 Design validation procedure & Quality process
19
Components Testing Methods Interpretation
Roll Cage Impact , Rollover , Torsion test Max stress 359 MPa
Suspension Drop test Max deflection is noted
Steering Minimum turning radius at figure of 8 Turning radius 2.32 m
Brakes At max. Speed ,brakes are applied Stopping distance 16.2 m
Transmission Ideal torque testing on wheel, at max acceleration & at max speed Tractive force-2058.4 N

DFMEA
Systems Failure Mode Effects Action Taken S O D RPN
Transmission Twist and Buckling of Power loss and vehicle CV joint with transmission shaft 9 2 8 144
Rod transmission shaft breakdown
Brakes Reduced Friction Between Pad Decreased brake Brake pads cleaned after 6 7 6 264
and Disc effectiveness and stability Specific time
control
Steering Tie rod bending or break down Loss of directional control Strong front bumper 9 7 8 504
 
Frame Excessive Load Driver safety compromised FEA with good FOS 9 4 6 216
, Vehicle break down
Suspension Buckling of spring Drive comfort and stability Design of spring at maximum 6 3 7 126
reduces possible load
 Facilities at College 20
&
Manufacturing Process
S No. Vehicle aggregates Process
1 Roll cage Pipe cutting
2 Roll cage Bending
3 Roll cage Grooving
4 Roll cage Welding
5 Mountings Cutting , drilling ,welding

S No Machines / Tools / Instruments Application

1 MIG welding machine Welding members in roll cage
2 Lathe machine Spindle and rotating jobs
3 Power saw Cutting pipes
4 Bending machine Bends to pipe
5 Engineering Files Groove on tubes
6 Grinder Finnish and rounding up edges
7 Drill machine Holes in mountings
8 Spirit level To maintain working plane
9 Tri square Maintain right angle
10 Tachometer To measure RPM of engine and wheels
 Team Composition & Work Allocation 21
S. Departments Departments Heads Members Particulates
No
Faculty Co-ordinator
1 CAD & CAE Sankalp Musale(C) • Harshad Gupta (OLD)
2 Suspension Rajkumar Thakur • Khushal Joshi • Mounting Asst. Prof. Himanshu Uppal
• Mithilesh Sharma • Testing
3 Steering Aditya Kothari • Shivankit Sood • Mounting (NEW)
Asst. Prof. Amit Prasad
4 Brakes Kapil Sharma • Abhishek Tiwari • Mounting
• Navneet Rathore • Testing S References
No.
5 Transmission Prasad Shirvalkar • Yogesh Rathore • Mounting
1 SAE INDIA BAJA Rule
6 Fabrication Abhishek Batane • Harpreet Singh • Welder Book 2015
• Manish Gandhi • Welder 2 Thomas D Gillespie(Vehicle
• Naman Sharma • Welder Dynamics)
• Apoorva Rawal 3 Milliken’s and Milliken’s
7 Procurement Nitin Bhadoriya • Akarsh Shrivastav 4 Dr. Georg Rill (Vehicle
& Marketing • Pritesh Sahu Dynamics)
8 Documentatio Urvashi Takkar • Supriya Mishra 5 Previous design report
n

Thank you
9 Electronics Puneet Shrivastav • Suryanshu Jain