Design Presentation

ROADIES
Regd. ID : 81341

National Institute of Foundry & Forge L/O/G/O

Technology , Ranchi www.themegallery.com
 TEAM ORGANIZATION
TEAM CAPTAIN
TEAM VICE-CAPTAIN
RICHARD DOLEY
AKSHAY TRIPATHI

TECHNICAL MANAGEMENT

UTSAV MAHTO KR. SAMBHAV

Design &
Analysis Fabrication Publicity Sponsorship Procurement

VIKAS UTSAV ANUROOP, RISHIKANT CHAITANYA DWIVEDI RAJ VARDHAN

RAJA,SATISH VISHAL PANDEY ANKIT GUPTA
ABHIMANYU ASHUTOSH

Tires &
Roll Cage Steering Suspensions Brakes

DHARMENDRA MANAS GOND

BITTU GUPTA HITESH GODWANI
RAJAT ROHIT UJJIR
 ROLL CAGE
Material Carbon Steel AISI 1018
DESIGN METHODOLOGY
UTS 365 Mpa
• Driver-oriented Cockpit design.
Carbon content 0.18%
• Light weight, Compact and simple.
Outside dia.: 25.4 mm
• High Roll stiffness and structural rigidity Wall thickness: 3.05 mm
• Easy egress during mishap.
• Least no. of welds and members

WELD JOINTS
 Number of weld joints = 62
 Weld length = 4.787 m
Roll Cage Analysis (Software: ANSYS 13.0)
Front Impact Analysis
 At Speed : 60 km/hr (16.67 m/s)
 Impact Time : 0.1 sec
 Thus, Load= 60000 N on front members.
 Max STRESS : 174 Mpa
 Max DISPLACEMENT : 2.38 mm
 Factor of Safety: UTS/Smax = 365/174
= 2.1

Side Impact (Safe case of Side Roll over)

 Load: 2G loading (6180 N) on side members.
 Max STRESS : 69.4 Mpa
 Max DISPLACEMENT : 2.26 mm
 Factor of Safety : 365/69.4
= 5.25

Roll Over (Dynamic) Analysis

 Load: 2G Horizontal on side members
1G Vertical on top members.
 Max STRESS :136 Mpa
 Max DISPLACEMENT : 5.5 mm
 Factor of Safety : 2.68
 Suspension: Double Wishbone Parallel SLA
FRONT LOWER ARM

SHOCK MOUNTING Front Lower arm , centre

REAR UPPER ARM LOCATION: Rear Upper arm, inner

LENGTH OF A ARMS: Upper arm 312 mm

Front Lower arm 338 mm
Rear Upper arm 263 mm
Lower arm 287 mm

ROLL CENTER HEIGHT: Front 81.66 mm

Rear 114.82 mm
 Steering
• Rack and Pinion; simple design and easy to install.
•100% Ackermann geometry

Target Specifications:
Gear Ratio 12:1
Caster 5° Positive
Camber (static) 2° Negative
Toe-in 10 mm
King-pin Inclination 12°
Scrub Radius 44 mm
Lock Angle 40° (approximately)
No. of turns to steer from Extreme Left 2.66 turns
to Extreme Right
Turning Radius
 Braking System
Maruti 800 calipers and disc will be used
Features:
Hydraulic disc brakes
Two independent braking circuit
Equipped with SMART Turning Assistance System
Two servo motor assisted valves on rear circuit.
While turning left, on application of brakes will lock both the
front wheels and rear left wheel.
Rear right wheel with drive will get moment along these 3 locked
wheel hence turning would be easier.
Target Specs:
Pedal Ratio 6.2:1
Braking Effort 1300 N per wheel
Deceleration 7.53 m/s2
Stopping distance 21.5m (max speed 60 km/h)
Assumption: Brake Efficiency = 70%
Coefficient of friction =0.65
Formula used ῖ = BfwR/r Bf = Mag s = v2/ 2gaₓ/g
 Power Train
Briggs and Stratton Engine:
10 hp OHV Intake

20S332 0036 New engine

with 3800rpm

Overhead Valve Design (OHV)

Runs cooler and cleaner delivering

more power, longer engine life and Torque* (ft-lbs,
14.50
improved fuel economy gross)
Engine
305
Displacement (cc)
Number of
Single
Cylinders
Flange Coupling Engine
Horizontal Shaft
Configuration
Engine
OHV
Technology
Length (in) 12.3
Width (in) 15.4
Height (in) 16.4
Weight (lbs) 50.4
Bore (in) 3.12
Stroke (in) 2.44
Engine Fuel Gasoline
SPARK PLUG RC12YC
 Safety & Ergonomics
Racing type 3 ways
Adjustable seats, for
driver comfort.
5 point harness seat
belt system along with
neck restraint and arm
restraint
Belly pan running entire
length of cockpit, Roll
cage foam padding and
body panels will be
provided
Fire extinguisher within
the reach of driver will Belly pan and Roll
be provided cage padding
Kill switches will be installed
to kill the ignition in case of
Pivoted bumper with spring
emergency
support in front
of vehicle to absorb energy
from collisions
SAE grade brake lights
will be installed and all
wiring will be properly
insulated and clipped.
All rotating parts will be
properly shielded with sheet
metal. Splash shields and Drip
pans will also be provided
Gear indicator to
enable quick gear
shifts
Design Specifications
Overall length 2.3 m
Front: 1.55 m
Track width
Rear: 1.45 m
Wheel base 1.60 m
Overall weight 310 Kgs (inclusive of Driver)
Engine Briggs and Stratton 10hp OHV
Transmission Mahindra Alfa(modified)
Tires 22 x 8 inches, 6 ply ATV
Rims 10 x 6 inches
SAE 1018 seamless steel tubes
Roll Cage
1” OD and 3 mm wall thickness
Double Wishbone suspension
Suspension (front and rear)
(Parallel and unequal arms)
Customized Centered Rack and Pinion
Steering System
Gear Ratio = 12:1
Braking (front and rear) Hydraulic Disc brakes
Maximum Torque 19 Nm @ 2900 rpm
Maximum Speed 60 KMPH
2-D views
Final View
 Design Validation Plan
No Description Accomplishment Allotted Means Of Accomplishment
Targets Resource
Welding test Strength of welded Abhimanyu Universal Testing machine
1.
components should be within Yadav
permissible limits.
Ground Clearance Should not be less than the Ashutosh 10 inch Spacer.
2.
Test specified value i.e. 10 inch Saraswat

Braking Test The vehicle should stop within Ankit Gupta To be tested on track with 2 different observers
3. for wheels on each side. Braking distance to be
safe limits and all the wheels
should be locked measured from point of brake application to
point of stop.

Wheel Travel Should be at least 6-7 inches Raja Sah Ruler

4
(jounce rebound)

Straight Line Stability Should move in a straight line Rohit Ujjir Driving the car in neutral steering position
5. parallel to the white strips on road.
when steering is at neutral
position.

Turning Radius Should be approximately Anuroop Radius will be measured using measuring tape.
6.
equal to the calculated value. Kulshresta

Fuel Leak Test Should not leak fuel or fluid at Vishal Pandey Vehicle should be tested in various roads
7. conditions and any case of spills to be
any circumstances.
scrutinsed.

Speed and By recording the time travel Hitesh Godwani Obtained data shall confirm the calculated
8. value
acceleration test while traversing a path
 College & External Facilities
MACHINING
Center Lathe
Universal Milling Machine
Grinding Machine
Drilling Machine
WELDING
Metal Inert Gas welding machine
TIG welding machine
Electric arc welding machine

MANUFACTURING MACHINES
CNC Milling Machine
Hot Isostatic Press(HIP) Machine
Rapid Prototyping Machine

TESTING MACHINES
Brinell Hardness testing machine(3000 kg)
Universal tensile testing machine(60 tonne)

EXTERNAL FACILITIES:
CNC Pipe Bending.
Laser Cutting (for hubs).
Paint Equipment.
Project Plan
Cost Estimates
Category Items Cost
Frame Steel tubes, Sheet Metal, 37,200
Welding supplies, roll cage
padding etc
Power Train Engine, transmission, shifters, 47,000
chains, sprocket, couplings etc

Wheels and tires Rims & tires(4+2) 39,900

Suspension Shocks, springs, A arms, uprights, 22,000
hubs, spindles

Steering Rack & pinion, steering column, 11,600

steering arm, steering wheel, tie
rods etc

Safety equipments Driver’s suit, helmet, fire 37,500

extinguisher, harness system,
restraints, kill switch etc

Braking Calipers, master cylinders, servo 14,500

motors, brake lines etc

Misc Travel, transportation, 30,000

accommodation etc

Total 2,39,700
THANK YOU!!!