FACULTY COLLEGE OF ENGINEERING DEPARTMENT OF … · 2018-06-01 · 1 suraj s d founder & ceo, rectangle automotive 2 ramchandra b kulkarni consultant, rectangle automotive 3 vijay

FACULTY COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING

In association with

RECTANGLE AUTOMOTIVE TECHNOLOGIES

PRESENTS

30-DAY INHOUSE RALLY CAR BUILDING INTERNSHIP

10th April to 9th May 17

BRIEF REPORT

RESOURCE PERSON DETAILS

SI NO NAME OF THE GUEST DESIGNATION

1 SURAJ S D FOUNDER & CEO, RECTANGLE AUTOMOTIVE

2 RAMCHANDRA B KULKARNI CONSULTANT, RECTANGLE AUTOMOTIVE

3 VIJAY THARD CONSULTANT, RECTANGLE AUTOMOTIVE

4 JOYTHIVANNAN SENIOR ENGINEER, KGTTI

5 AVINASH IDEAL MOTORSPORTS

6 RAJATH KATTIMANI TORQUE AUTOMOTIVE SOLUTIONS

7 VIDYASAGAR INTERN, RECTANGLE AUTOMOTIVE

8 SUHAS R INTERN, RECTANGLE AUTOMOTIVE

9 ANISH BIWAS INTERN, RECTANGLE AUTOMOTIVE

Week 1

Interns have undergone theoretical and practical training on IC engines, sensors, actuators, engine cooling,

lubrication, exhaust systems and turbo-charging. Activities are performed to make sure every individual intern have the

assessment sheet for each module. And interns are guided one on one from trainer. Such, every individual point out the

sensors position, function, failure cause & trouble shooting.

Mr.Vijay Thard and Suraj S D have engaged the training for the contents. First 3 days of the training have

brought up the confidence in interns to physically know all the physical components of above mentioned topics.

Interns have formed into team of 5 and involved in measuring the dimensions of the vehicle such as

wheel base, turning radius, front & rear overhang, departure & arrival angles. Significance of all the physical

parameters have been taught by trainers.

Vehicle dimension activity sheet.

Tyres

Followed by training modules on automotive tyres. Module consist of understanding the tyre terminology,

specifications, types, applications, tyre failure and cause analysis for the failure. Team of 2 interns have given with the

activity sheet and set of tyres after the theory sessions to perform the detail understanding of all parameters.

Car dis-assembly

Activity involves interns to dis-assemble the exterior components of the car such as bumper, front grill,

fenders, rear bumper & wheel cover.

Under-body systems

Dis-assembly of Engine guard, exhaust systems and lighting system

Week 2

Welding training

Expert from Karnataka German Technical Training Institute has engaged the training for welding

module. Module consist of practical and theory sessions on MIG and ARC welding.

Tube Notching theory

Activity to perform tube notching for 900, 600 & 450 and further to perform welding to join notched

pipes.

Tube Notching practical’s

Preparing the workpiece for tube notching, each intern practiced the notching activity for different

angles. Tube welding is practiced for the same workpiece.

Suspension dis-assembly

Dis-assembly of antiroll-bar, torsion bar and suspension dis-assembly practice. And session on

suspension has been delivered by Vidyasagar. Suspensions components, variants and different set-up for

suspension on racing and rallying.

Training on Brakes and Suspension

Roll-cage design

Roll-cage serves the primary function to provide the safety for the driver & co-driver. FIA defines the

regulations for roll-cage design, students have taught on how to take dimensions for roll-cage design and

interns have created the 1:1 scale drawings.

Week 3

Interns have involved in dis-assembling the engine from the car and strengthen the chassis to mount

the roll-cage in tandem team of students have built the 1:1 prototype of the roll-cage.

Chassis strengthening

Engine Dis-assembly preprations

Engine dis-assembly from car

Dis-assembling engine have been the wonderful experience for interns.

ECU Tuning

Rajath, Torque motors, explained interns about ECU tunings and re-mapping in order to enhance the

vehicle performance in the rally. During the course students have practiced the tuning and trainer have

provided the ECU maps of Skoda Octavia. Rajath explained about the hardware and software necessary to do

tuning. Demo of the map extraction done on NISSAN Micra.

Week 4

During week 4 interns have involved in mounting the roll-cage, assembling the interior and exterior

parts, assembling the engine back to car. To overview the rally and building the car, idel racing from bangaluru

has brought the rally build Esteem, students had the opportunity to discuss with the team on tuning done on

the vehicle and ECU maps, suspension modifications and adjustments. Team have let the opportunity for few

students to sit on the co-driver seat to experience few rally driving modes.

Roll-cage installation

Tube bending is done using CNC bending process, team of students visited facility at peenya with 1:1

scale prototypes. During the bending, settings for bending, bend angles, die radius and requirement of the

bending were taught.

Interns have finished the mounting of roll-cage, assembling the engine, exterior and interior parts and

suspension. Built up rally car has been driven for functionality.