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SUSPENSION STIFFNESS
REAR
Modulus of rigidity of spring G = 80000 N/mm
2
Diameter of spring = 12mm
Radius of coil = 50 mm
No. of coils = 7
Hence stiffness
n R
d
K
3
4
64
o
= = 26.62 N/mm
Static load on each rear wheel = 1038.80 N
for a load of 1038.8 N
Travel cm 67 . 4
256 . 22
8 . 1038
= = o
Hence travel while mounting = 35.1 mm
Weight transfer calculations
Due to braking, weight transfer occurs and this depends
on the deceleration of the vehicle. During maximum
deceleration, weight on the front wheels is more
compared to rear wheels.
Total weight of the wheel, Kgs w
total
350 =
Static weight on the front axle,
front
w = Kgs 105
Height of C.G of the vehicle, h = 467.5 mm
Wheel base, l = 1676 mm
Maximum deceleration of the vehicle during braking,
d
x
= 7.61 m/s
2
Similarly,
total
x
rear
rear w
l
h
g
a
w w
|
.
|
\
|
|
|
.
|
\
|
=
'
Static weight on the rear axle,
rear
w = Kg 245
18 . 169 350
1676
5 . 467
8 . 9
61 . 7
245
'
=
|
.
|
\
|
|
.
|
\
|
= rear w
Percentage of Weight transfer,
66 . 21 100
1676
5 . 467
8 . 9
61 . 7
% =
|
.
|
\
|
|
.
|
\
|
= weight
Therefore 21.66% of weight transfer occurs at maximum
acceleration of the vehicle
FOR MAXIMUM INCLINATION THE VEHICLE
CAN CLIMB IN STATIC CONDITION
Assume no speed condition at rear wheel; vehicle will
topple when reaction at front axle will become zero.
When R 0
= =
h
b
u tan distance of C.G from rear axle/ height
of C.G
467 . 0
508 . 0
=
= 47.38
0
MAXIMUM POSSIBLE ACCELERATION
uH - L
gua
=
x
a =5.428 m/s
2
CALCULATION FOR DISC BRAKE DIMENSION
R
o
= Outer disc radii
R
I
= Inner disc radii
=0.3
T= torque acting on single wheel
P = pressure applied by brake fluid.
total
x
front
front w
l
h
g
a
w w
|
.
|
\
|
|
|
.
|
\
|
+ =
'
kg w front 81 . 180 350
1676
5 . 467
8 . 9
61 . 7
105
'
=
|
.
|
\
|
|
|
.
|
\
|
+ =
= included angle of caliper disc contact
T= | |
3 3
3
2
i R R P o u ...(1)
45 . 1
R
R
i
o
= ..(2)
Substituting (2) in (1)
12.69cm R and
8.78cm R
3 . 0 4375 . 2253 R
o
i
i
3
=
=
=
The torque produced is calculated from the maximum
deceleration the vehicle can achieve while braking. The
resultant dimensions of the disc were a close
approximation to the disc size of Maruti800 and hence it
was selected for our vehicle.
LIMITING VALUE OF INCLINATION FOR
ABOVE ACCELERATION
u sin max g a =
5.428+9.8sin =
0.4675
) sin - (1 0.508 9.81
2
u
207.8756 u
2
sin + 106.497 u sin = 84.1726
u sin = 0.43, - 0.94
u sin = 0.43
u = 25.47
0
Hence the vehicle can safely climb a hill of more than 25
degrees with maximum acceleration. However the actual
inclination that could be climbed(with less than
maximum acceleration) will be much more than the
given value.
APPENDIX B
VIEWS OF FINAL VEHICLE
Figure 3(A) Top view Figure 3(B) Front view
Figure 3(C) Side view
Figure 4 Isometric view
APPENDIX C
RESULTS OF CFD SIMULATIONS
Figure 5 contours of static pressure on car body and road
Figure 6 Pathlines emitted from the car body showing turbulent flow field aorund the vehicle
APPENDIX D
Figure 7 Exploded view of wheel end
(A) Rear (B) Front
To pedal brake On/Off valve
Front
Master cylinder
Oil reservoir To hand brake
Figure 8 Circuit diagram of hydraulic brake