Detailed Specifications

These are the detailed specifications of the car.

ROLL CAGE
The basic structural members of the roll cage like RRH, FBM, RHO, Lateral Diagonal Bracings (LBD), Side Impact Members (SIM) and Front Lateral Cross Members (FLC) will be made up of 1.125 inch Outer Diameter (OD) 0.120 inch thickness steel (As prescribed in the rule book AISI 1018) pipes and the supporting members will be made up of 1 inch OD and 0.120 inch thickness steel (As prescribed in the rule book AISI 1018) pipes. For the analysis the tensile strength (=420 MPa) modulus of elasticity (=205 GPa) and yield strength (=350 MPa) were used in material properties. All possible cases of roll cage impact were studied and safety tests for the roll cage under each circumstance was analyzed and the results are summarized below.

SUSPENSION
A double wishbone design was chosen to accomplish this for a variety of reasons. This system has the versatility that allows for its design to meet required specifications. ADAMS/vehicle dynamic modeling software was utilized to analyze countless combinations of these variables. The software allows for the quick change of A-arm lengths, hard point positions and shock characteristics so that any configuration can be achieved and studied. This analysis involved determining the best balance between the roll center and camber curve, where usually one is sacrificed for the other. The finite analysis of the front suspension system was carried out using Finite Element Analysis (FEA) software ANSYS.

UPRIGHT

The Front Suspension upright design was completed in SolidWorks and its analysis was done in ANSYS. The upright was analyzed assuming fixed at the mounting ball joints and experiencing an upward force of 6000N. The max value of stress obtained was 52.3 Mpa much below the Tensile Yield Strength of 250 Mpa of structural steel.The team decided to use an innovative independent rear suspension assembly with a shaped suspension arm joint at the front to the chassis, allowing the rear to swing up and down. It has a distinct advantage over the double wishbone system because it doesn't suffer from the side-to-side scrubbing problem of double wishbone systems. An anti roll bar is also being incorporated into the rear suspension system to provide stability & to prevent complete rollover of the vehicle. The finite analysis of the rear suspension system was carried out using Finite Element Analysis (FEA) software ANSYS keeping the suspension system fixed at the hinges and assuming that the upright assembly experiences a force of 6000 N.

HUB
The design and analysis of tyre hub has also been completed by the design team. The hub design was completed in SolidWorks and its analysis was done in ANSYS. As the maximum torque that the engine offers is 19 N-m or 1.9 Kg-m, the analysis was done considering the max torque transfer through one hub. The material used is cast iron. The resultant stresses obtained were well within the tolerable limit and no indication of any kind of design failure was seen.

STEERING
A customized rack and pinion steering with a steering ratio of 18:1 will be used by the team. Various analysis were carried out using ADAMS/CAR for the suspension and steering system results of which were considered while deciding the Camber, Caster & Kingpin Inclination Angles. Other factors such as suspension geometry, kingpin inclination and scrub radius also affect the steering capabilities of the vehicle and were also be examined to achieve the best possible steering geometry.

TRANSMISSION
Being a debutant in this competition and due to our inexperience in assembling drive train systems Team Knox decided to use the tried and tested transmission of Mahindra Champion Alfa both due to its relative ease of assembly and its ready availability. GEAR RATIOS Gear ratios of the M&M Champion Alfa Transmission are shown below: 1 ----- 31.48:1 2 ----- 18.70:1 3 ----- 11.40:1 4 ----- 7.35:1 R ----- 55.08:1 Page 2 of 2 12

Our mission
The objective of the Baja competition is to design and manufacture a fun to drive, versatile, safe, durable, and high performance off road vehicle. The vehicle must be capable of negotiating the most extreme of terrains with confidence and ease.

Title

The Car Innovations Apart from the innovations in the suspension system, i.e. the trailing arm and the anti roll bar the team plans to install an automatic engine cooling system based on a simple thermostat connected to a battery and a fan which comes into action whenever temperature near the engine exceeds a certain value.
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