TEAM ORGANIZATION CHART

TEAM CAPTAIN

Anirudh Bagde
PROJECT PLAN
 KNOWLEDGE OF RULE BOOK

The SUPRA SAEINDIA STUDENT FORMULA competition challenges teams of university

undergraduate and graduate students to convince ,design , fabricate ,develop and
compete with small, formula style, vehicles.

• The vehicle must meet all the safety parameter as per rule book.
• Purpose of competition is to lead teams to design ,fabricate ,test and demonstrate
a prototype vehicle for non professional weekend competition market.
• Vehicle must be open wheeled and open cockpit with 4 wheels not in straight line.
• Minimum wheelbase 1525 mm (60 inches)
• Smaller track of vehicle must be no less than 75% of larger track.
• All inspection holes must be clearly visible.
• Car must be equipped with a full operational suspension system with shock
absorber usable wheel travel of at least 2 inches
• Wheel of car must be 203.2 mm (8.0 inches) or more in diameter.
• Steer- by-wire is probhited.
• Brakes must act all four wheels.
• Total engine displacement cannot exceed 610 cc and air must pass through a
single air intake restrictor.
 DESIGN METHODOLOGY

• Steel space frame

• Main hoop and front hoop OD 25.0mmX2.50mm wall
thickness
• Side impact and bulkhead & Roll hoop bracing OD
25.0mmX1.75mm wall thickness
• Front bulkhead support & main hoop bracing support
OD 25.0mmX1.50mm wall thickness
• High torsional stiffness

MATERIAL SPECIFICATIONS

• Material used- SAE AISI 1018 STEEL

• Yield strength- 370 MPa
• Young’s Modulus- 210 GPa
• Ultimate strength- 440 MPa
• Poisson’s ratio- 0.29
• Density- 7800 kg/m^3
FINITE ELEMENT ANALYSIS
Front impact
• Vehicle travelling at maximum
speed(80km/h) collides head on
with a stationary object in a crash
impulse of 0.4 seconds.

• Force applied: 11000 N

• Factor of Safety: 2.7

Rear impact

• A moving object collides with the

rear of stationary vehicle with a
speed of 80kmph and a crash
impulse of 0.8 seconds.
• Force applied: 7500 N
• FOS: 3.6 (for engine safety)
FINITE ELEMENT ANALYSIS
Side impact
• A moving object collides on the side
impact members of stationary vehicle,
with a speed of 80 km/h with a crash
impulse of 0.6 seconds.
• Force applied: 6950 N
• FOS: 2.6

Rollover
• Vehicle cornering with a speed of
40 km/h with a turning radius of 15
m.
• Force applied: 1000 N
• FOS: 1.6
 HUMAN ERGONOMICS

• Real time PVC prototyping

• Good vision,
• Adequate cockpit size,
• large foot-well area and comfortable sitting and
restraints.
• Designed according to 95th PERCENTILE MALE TEMPLATE
 SUSPENSION

• Push rod suspension for both front and rear.

• Fully independent outboard suspension, unequal length, non-parallel,
double A- arm design.
• The A-arms do not mount directly to the nodes but are mounted as
close as is practical so that minimal bending is introduced into the
chassis.
• Suspension has been analyzed using Altair hyper work.

FRONT SUSPENSION
 SUSPENSION
REAR SUSPENSION

RESULTS FROM SUSPENSION ANALYSIS

FRONT REAR
ROLL CENTER 4.20 mm 37.24 mm
KPI 7.15 degree 5.01 degree
CAMBER -2 degree 0 degree
SCRUB RADIUS 48.79 mm -0.38 mm
WHEEL RATE 36.25 N/mm 72.09 N/mm
 UPRIGHT ANALYSIS

MATERIAL USED: Aluminum 6061 T 6

FRONT UPRIGHT REAR UPRIGHT
FOS: 16.16 FOS: 5.37
Maximum deflection: 0.0310 mm Maximum deflection: 0.203 mm
 HUB ANALYSIS

Hubs were analyzed for maximum acceleration.

The maximum torque due to engine was 865.5 Nm,
and a corresponding force of 8655 N was applied
tangentially at the wheel mounting points.
Total force=8655N(due to torque)+3433.5N(due to
weight transfer)

MATERIAL USED:
Aluminum 6061 T 6
Same material was used to reduce purchasing costs.
SPECIFICATIONS:
Wheel mounting pitch circle diameter : 100 mm
Rotor mounting pitch circle diameter : 110 mm
Bolt diameter: 10 mm
 STEERING

Steering type Custom made Rack And Pinion Steering

Steering Ratio 8:1

Steering angle 35 degree

Turning Radius 3.5 m

Caster angle 4 degree

Lock To Lock ratio 1.5 turns

Material Mild Steel

 BRAKING SYSTEM

• Disc brakes on all four wheels.

• Independent break circuit for front and rear wheels.
• Hydraulic operated disc brakes
• Brake disc size =220mm
• Stopping distance (40-0 km/h)= 6m(friction coefficient for tires taking as 1)
• Master cylinder(diameter)
Front :- 21.06mm
Rear :-19.22mm
• Pedal force – 207.5 N
• Pedal ratio - 4:1
 POWER TRAIN
ENGINE: HONDA CBR250R
Engine type CS250RE, liquid-cooled 4-stroke DOHC single cylinder
Displacement (cm³) 249
Engine Power 25bhp @8500 rpm
Engine Torque 22.9Nm@7000 rpm
Fuel supply system Programmed fuel injection system (PGM-FI)
Lubricating type Wet sump
Clutch type Wet multi plate with coil springs
Transmission type Constant mesh 6-speed return

DRIVE TRAIN
GEAR VELOCITY TRACTIVE FORCE(N) ACCELERATION
•Chain drive (520)
(m/s) (m/s2)

•Final drive ratio 3.57:1(50/14) 1 5.85 2868.73 8.2

2 9.21 1822.91 5.21
•open differential 3 12.41 1352.34 3.86
4 14.96 1122.23 3.21
5 17.49 959.96 2.74
6 20.26 828.59 2.37
 WHEEL ,TIRES & SAFETY EQUIPMENTS

WHEEL AND TIRES SAFETY EQUIPMENTS

Tire GoodYear 145/70R13 Equipment's Ratings

Rim HRS-H253 Full Machined
White13’ Alloy Helmet FIA 8858-Snell 2010
Approved
Size 13’*5.5’
Drivers suit FIA 8856-2000 Approved
Hub Custom made
Upright Custom made Harness (4point harness) FIA approved

Shoes FIA 8856-2000

Arm resistant SFI Standard 3.3

Fire Extinguisher Powder or any

extinguishant
homologated by FIA
 PERFORMANCE TARGET AND VALIDATION PROCEDURE

Performance Target Validation Procedure

Max Speed Targeted 80km/h Chassis Real time prototyping of chassis and
analysis of stress points
Acceleration 3.06 m/s2 Suspension the suspension is being analyzed using Altair
Hyperworks
Stopping distance 6m Steering ground testing

Weight of the car 320 kg Braking ground testing

Engine Dynamometer for power and torque figure

 COLLEGE WORKSHOP FACILITIES

•CNC Train Master Lathe •DRO Lathe Machine

•VMC Train Master
•CNC Turning Centre
•CNC Machining Centre
•Drilling Machine
•Universal Milling Machine
•Gear Hobbing Machine
•Ram Turret Milling Machine
•Lathe Machine With Different Sizes
•Capstan Lathe Machine
•Power Hacksaw Machine
•TIG Welding Machine
•MIG Welding Machine
•Spot Welding
•Plasma Cutting Machine
 COST ESTIMATION
AREA PRICE

• Engine & Drive train (ED) 150000

• Brakes(BR) 21112
SF
• Steering(SR) 4500 20%

• Suspension(SU) 40000 ED
39%

• Frame & Body(FB) 25000 MS

10%

• Wheels & Tires(WT) 25000

WT
•Miscellaneous(MS) 40000 7%

FB
•Safety(SF) 75275 7%
SU
BR
ST 6%
10% 1%

•Total
ED BR ST SU FB WT MS SF
380387
 VEHICLE SPECIFICATION

• Wheelbase - 1600 mm
• Height - 1332mm
• Track - F 1300mm, R1100mm
• Overall length - 2590mm
• Engine - Honda CBR250R
• Engine displacement - 249 cc
• Engine power - 25HP
• Ground clearance - 100 mm
• Steering - Rack and pinion
• Suspension - Push rod suspension
• Brakes - disc brakes on all four
wheels
• Material for frame - AISI1018