SUPRA SAEINDIA 2013 VIRTUAL PRESENTATION TEAM TERASVIN SONA COLLEGE OF TECHNOLOGY, SALEM

KNOWLEDGE OF RULE BOOK

For the STUDENT FORMULA competition, teams are to assume that they work for a design firm that is designing, fabricating, testing and demonstrating a prototype vehicle for the non-professional, weekend, competition market. Cockpit Opening &Cockpit Internal Cross Section must be as per the template. Firewall &Floor Close-out must be of suitable material as per the rules. Any portion of frame which might be in contact with driver helmet must be padded. The car must have a wheelbase of at least 1525 mm (60 inches). The smaller track of the vehicle must be no less than 75% of the larger track. The suspension system with shock absorbers must have minimum travel of 2 inches. The wheels of the car must be 8.0 inches or more in diameter. The steering wheel must be mechanically connected to the wheels. The braking system must act on all four wheels and be operated by a single control. Engine displacement Limitation is set to below 610cc. The throttle must be actuated mechanically, i.e. via a cable or a rod system. Intake System Restrictor of 20mm must be used. The maximum permitted sound level from the vehicle is110 dBA . The vehicle must be equipped with two (2) master switches which form part of the shutdown system.

TEAM ORGANIZATION CHART

SUSPENSION/FRAMES SUB LEADER:ANANDH AJAY KUMAR STEEERING SUB LEADER: ROSHAN THILAK RAJ ENGINE/DRIVETRAIN SUB LEADER: RAGAVAN KIRAN RAJ RAMPRASATH MOHAMED ARIF

TEAM LEADER: ANANDH

BRAKES SUB LEADER: ARIEF M KASHIF AHMED MARKETING SUB LEADER: ARIEF M PRADEEP

ELECTRONICS SUB LEADER: RAJESH PRADEEP RAGHU

PROJECT PLAN

Technical specs Dimensions : 2832x1397x1058 mm Wheelbase : 1572mm Suspension : Push rod actuated unequal double A-arm Brake : Parallel hydraulic actuation ventilated petal discs Frame : 4130 chromoly steel Steering : Rack and pinion Tires : 20.5x7.0-13 (Hoosier)

DESIGN METHODOLOGY OF ROLL CAGE

Steel Space Frame Suspension mounts are mostly nodded. Comply with all rule templates. Machine around the man concept.

Material Used SAE 4130 steel tubes.

Low cost, manufactured with conventional tools. Easy to repair and modify.

Inclined the drivers seat angle to get low CG.

SPECIAL FEATURES
High torsional rigidity of 4022Nm/deg. Weight of the chassis is less than 230kg. Factor of safety is greater than 2

for impact tests.

FEA

Load applied: 20,600 N Front impact FOS: 2.7

Load applied: 8830 N Rear impact FOS :2.4

Load applied : 14,720 N Side impact FOS:2.2

Load applied : 4420 N Roll over FOS:3.5

ERGONOMICS
Good visibility for the driver. Frame tracing the shape of human body. Large cock pit opening for quick exit.

Comfortable seating position.

Quick release steering wheel.

95th percentile male template

SUSPENSION
METHODOLOGY Push Rod Suspension Load transfer during braking, acceleration and cornering were considered. FVSA and SVSA geometry were used to finalise roll centre, instantaneous centre and finally mounting points were determined. Anti dive and Anti squat were considered during the design. Mounting points were mostly nodded. FR: 17.78mm Roll centre RR: 25.4mm SPRINGS AND DAMPERS
Based on requirements and availability

LINKARM DESIGN To obtain good camber curve

Stiffness Camber Roll angle

FR: 25.05 N/mm RR: 56.64 N/mm

-2.
. 0.124

SUSPENSION
Front lower control arm Rear lower control arm

FOS : 5.8

FOS : 6.4

Optimum K analysis Input :Static values Output : Dynamic conditions obtained

WHEEL GEOMETRY
Tyre specs 20.5x7.0-13 Slick tyres

UPRIGHT ANALYSIS

FRONT UPRIGHT

REAR UPRIGHT

FOS:2

FOS:3

HUB ANALYSIS
FRONT HUB Material : Aluminium 6061 T-6

STRESS

FATIGUE

FOS:5.5

REAR HUB Material: 4340 steel

STRESS

FATIGUE

FOS: 2.9

BRAKES
BRAKE LINING
Disc brakes on all four wheels Hydraulically operated braking system Independent front and rear brake circuit Parallel brake lining system MASTER CYLINDER Front bore : 15.8 mm Rear bore : 20.02 mm

DISC SPECIFICATION 200 mm ventilated petal disc Stopping distance: 3.9 m(40 km/hr) Pedal force : 1423.4 N Pedal ratio : 4:1 Brake efficiency : 85%

STEERING
Rack and Pinion Steering: Team Design and Manufacturing Steering ratio : 3:1 Maximum Turning Radius : 4.71m Steering Angle : 35 degrees Material : Mild steel caster : 7 degree

POWER TRAIN
ENGINE (HONDA CBR 600 RR) 599 cc Inline 4 cylinder Compression ratio 12:1 Electrically controlled Fuel injection DOHC 4 valve per cylinder 32 mm throttle body chosen 6 speed sequential transmission ENGINE STOCK PERFORMANE FIGURES Power : 105.6 hp @ 13,250 rpm Torque : 60.7 Nm @10,500 rpm Mounting points DRIVE TRAIN Chain drive (520) Final drive ratio 4:1 Torsen limited slip differential DOJ type CV joint

POWER TRAIN
INTAKE SYSTEM Top Feed Intake system plenum volume set two times the engine displacement Runner length calculated to optimize power. Flow analysis done for even distribution of mixture Runner length : 256 mm Runner diameter : 38 mm EXHAUST SYSTEM 4-2-1 configuration Reduced Back pressure Free flow muffler Lowered sound level

ELECTRONICS
ELECTRONIC CONTROL UNIT RD 0901 ADDITIONAL ELECTRONIC KITS Speed meter RPM meter Malfunction indicator

Gear indicator
Gear shifting indicator

GEAR SHIFTER
GEAR SHIFTER FEATURES Shift timing :30 ms Ignition interruption

SAFETY EQUIPMENT RATING

EQUIPMENT PADDING HELMET
DRIVER SUIT SHOES ARM RESTRAINT FIRE EXTINGUISHERS DRIVER RESTRAINT SYSTEM

EQUIPMENT RATING SFI spec 45.1 or FIA 8857-2001 Snell K2000,SFI 31.2A or FIA 8860-2010 SFI 3-2A/5, FIA Standard 1986 FIA Standard 8856-2000
SFI 3.3, FIA 8856-2000 SFI Standard 3.3 Powder extinguishant homologated by the FIA SFI Specification 16.5, or FIA specification 8853/98

OVERALL PERFORMANCE TARGETS AND VALIDATION PROCEDURES

PERFORMANCE TARGETS Engine power Engine torque Estimated top speed Acceleration Stopping distance : : : : : 75 HP 55 N-M 140 KPH 4.2 sec for 0-75 meters 3.9 m

VALIDATION PROCEDURE & TESTS TO BE PERFORMED Engine : Dynamometer for power and torque figures of the vehicle. Braking: Chassis Dynamometer. Chassis: Real time prototyping will be done to test the key points for strength. Vehicle leakage test Torsional rigidity test Noise level testing

COLLEGE WORKSHOP FACILITIES

CNC LATHE (INDUSTRIAL MODEL LT16) WIRE CUTTING MACHINE (EDM) CONVENTIONAL LATHE (TURN MASTER 35 KRILOSKAR) CAPSTAN TURRET LATHE MILLING MACHINE HORIZONTAL AND VERTICAL SHAPING MACHINE MEDIUM AND HEAVY DUTY RADIAL DRILLING MACHINE

UNIVERSAL TESTING MACHINE

TORSION TESTING MACHINE FATIGUE TESTING MACHINE COMPUTIRISED I.C ENGINE LAB & DATA ACQUISITION SYSTEM

COST ELEMENTS AND SPONSORSHIP

AREA BR EN FR EL MS ST Brake system Engine&drivetrain Frame & Body Electricals Miscellaneous Fit & Finish Steering system TOTAL (RS) 13040.00 227380.00 99455.00 133320.00 84400.00 3520.00 OUR SPONSORS TILL DATE

BR

EN
FR EL MS ST SU WT
SONA COLLEGE OF TECHNOLOGY THE PROFESSIONAL COURIERS JK CEMENTS

SU
WT

Suspension, shocks
Wheels & Tires Total

57780.00
74600.00 693495.00