Sae Baja 2012 Design Report Team Gearedup

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  • Topic: Brake, Suspension, Steering
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  • Published : July 22, 2012
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TEAM GEAREDUP - 96745
DKTE’S Textile and Engineering Institute, Ichalkaranji Kolhapur.

19th AUGUST 2011

SAE BAJA - 2012
Team Captain Saddam Hussain (B.E. Mechanical)

Faculty Advisor Prof. Mr. A. R. Balwan

RULE BOOK IMPORTANT PARAMETERS
PARAMETER TRACK WIDTH WHEEL BASE MAXIMUM SPEED MATERIAL STRENGTH DRIVER HEAD CLEARANCE          ALLOWED 64 INCH 108 INCH 60 Km/Hr 365 Mpa 6 Inch SELECTED 46 INCH 67 INCH 45 Km/Hr 480 Mpa 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.

DIMENSIONS: Length= 87 inch Width= 33.02 inch MATERIALS: WEIGHT:

CHASIS…

Height= 48 inch At front end= 13.4 inch At rear end= 15 inch OUTER DIAMETER: 33 mm THICKNESS : 3 mm

Steel IS 1239

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 .

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

L-CHANNEL

 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.

6 Deg

SIDE

FRONT

TOP

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

48 inch

12 inch

FRONT VIEW

SIDE VIEW 66.8 inch

46 inch

ISOMETRIC VIEW

TOP VIEW

TRANSMISSION
ENGINE SPECIFICATIONS: Lombardini LGA 340
Rated Power: 8 kW at 4400 rpm Max Torque: 19 Nm at 3000 rpm

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 : 1ST - 6.8 TO 10.06 Km/hr 2ND -11.55 TO 16.94 Km/hr 3RD - 18.94 TO 27.78 Km/hr 4TH - 29.38 TO 43.10 Km/hr REVERSE – 3.92 TO 5.75 Km/hr

TYRES : DIAMETER 24 INCHES , WIDTH – 12 INCH
ATV TIRES

WHEELS :
R15-SKODA

BRAKES
REAR : Internal Expanding Shoe Brakes FRONT : Disc Brakes Weight falling on each rear wheel 48 kg

SR NO.

V

R

F(braking)

f(deceleration)

(km/hr)

(N)

(m/s2)

1. 2.
3. 4. 5.

50 50
50 50 50

1 .55
.45 .40 .35
f (m/s2) 2.99 4.7 4
5.45 4.7 4 5.45

808.525 1281.86
1473.56 1593.66 1899.73
R – R’(N) 290.63 460.7 3
529.7 4 460.7 3 529.7 4

2.99 4.74
5.45 5.89 7.03
S(m) 32.26 20.35
1 7 .7 1 6.48 1 4.33

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. 1. 2.
3. 4. 5.

V(Km/hr) 50 50
50 45 45

6. 7. 8.
9.

45 35 35
35

7 .03 5.45 5.89
7 .03

683.32 529.7 4 57 2.51
683.32

1 1 .11 8.67 8.02
6.7 2

SUSPENSION
SUSPENSION DEMANDS: Ground clearance to be 11-12 inches
PARAMETER spring rate
Total number of coils Number of active coils

19.71 N/mm
15.00

13.00

FIGURE FROM SUSPROG SOFTWARE

Wire diameter Free length solid length solid load

11.00 mm 390 mm 150 mm 4827.22 N

STEERING
For steering calculations we used Susprog...
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