presentation on car for SUPRA event

Team Vega Supra SAE INDIA Student Formula Team

JSS Academy of Technical Education, Noida

Team Formation

Ergonomics and Structure

Right Side View Top View

Front View

Material specification: IS 3074 Material specification: ASTM 106b

O.D. : 1”. O.D. : 1”.

W.T. : 0.065”. W.T. : 0.095”.

Youngs’ Modulus : 200 GPa. Youngs’ Modulus :

Yield Strength : 373 MPa. Yield Strength :

Density : 7860 kg/m3. Density : 6100 kg/m3.

Materials Options available

IS 3074

AISI 4130

ASTM 106

AISI 1018

Material and Design

• Optimum level of triangulation and tetragonal design.

• Structural side pods for rigidity and side impact safety. • Being light weight but cost effective material.

• Compact inclusive of all systems packaging.

• High torsional rigidity.

Analysis & Simulation Sr. no.

Test

Boundary conditions

Force moments

Magnitude

Von Misses Stress (N/m2)

Factor Of safety

1. Static Shear Clamp rear suspension mounts

Downward force at front bulkhead

1440 1.08e+008 3.01

2. Static Overall Vertical Bending

Clamp- front and rear suspension mounts

Uniformly distributed loading

1500 1.48e+008 4.18

3. Static torsional loading

Clamp- rear suspension mounts

Clockwise Moment at bulkhead side

310 0.79e+008 7.81

4. Front Impact analysis

Clamp- front and rear suspension mounts

Suspension Geometry

• Wheel base – 1600mm • Track width – 1300mm • Four wheel independent. • Double A Arm with pushrod actuation

on front. • Provides desired motion ratio

with easy adjustability. • Max. load is transferred to the springs. • Reduces drag.

• Double A Arm with direct acting springs on the rear. • Provides the required stability. • Packaging constraint is dealt with.

• Static Roll Centre height of 45mm with FVSA 1731mm.

• Static Camber of 2 degree negative.

Suspension – Linkages, Spring and Damper

• Usable wheel travel aimed at 60 mm. • Desired motion ratio of 1:1. • Wheel Rate(N/mm) = Load(N)/Deflection(mm) • Wheel rate

• Front – 18.312 N/mm • Rear – 27.468 N/mm

• The spring with required stiffness and travel can be determined.

• Design criterion for A Arms

• Must provide the desired kinematic characteristics. • Strength should be high to bear the required loads

with sufficient factor of safety.

Force Diagram

Steering

• Minimum turning radius is 2.5meter.

• Steering ratio 8:1 was assumed to be

good considering both the factors,

driver handling as well as fatigue.

• Lock to lock angle of wheel is 67.7°

• C-factor for given steering system is 120mm. • Selected steering axis inclination for

negative scrub radius not more than 10mm was 3° .

• Mechanical trail for the front tires is 28mm .

Other parameters – *Above parameters are at static condition.

Brake system • Weight Transfer –

• Disc brakes(hydraulic) was selected for brake system.

• Maximum retardation of the vehicle is “ g”.

• Distance travel by car in brake test (40 - 0kmph) is 6.9metre.

• Pedal force require to stop the vehicle 207.5N .

• Other Parameters –

• Selected pedal ratio for desire play of

brake pedal was 4:1

• Maximum efficiency is 98% for µ=1

and it is 88% for µ=0.7

• Thermal Analysis of rotor- • Maximum Temperature of the disc

is 224.57 °C

Engine & Power train Engine: HONDA CBR 250R Comparison between CBR-250R & RE-500

Selection of Honda CBR-250R over RE-500 • Power to weight ratio • Power band lying in desired rpm range • Low emission level:

1. Secondary air supply system 2. Three way catalytic convertor

Drive train unit: 6 speed transmission

Gear Gear Ratio Tractive Force (N) Acceleration (m/s2) Velocity (m/s)

1 3.33 3443.113 10.43 4.72

2 2.12 2188.909 6.63 7.43

3 1.57 1624.363 4.92 10.02

4 1.31 1348.94 4.08 12.07

5 1.12 1152.87 3.92 14.12

6 0.96 994.627 3.01 16.37

Primary reduction=2.808:1(73/26) Final reduction=4:1(56/14)

Restrictor design: Converging-Diverging geometry with throat of 15mm. • Optimization of restrictor is carried out to get

minimum pressure drop across it. • Numerous iteration were carried out in Ansys fluent

as shown below.

Maximum mass flow rate: 0.02976 kg/s Mass flow rate for choked condition: 0.0726 kg/s

Intake manifold design

Static Pressure V/s Position

Contours of velocity magnitude (m/s)

DFMEA & DVP

Project Management

Phase I Design & Fabrication

July-November

End Semesters (GAP)

December

Phase II Design & Fabrication

January-March

Phase III Testing & Optimization

April-June

Cost Plan

BREAK EVEN ANALYSIS for B-PLAN • Fixed cost, x-units of production, Variable Cost,

Selling Price per unit, Total Sale Revenue.

• At BEP, x = F/(s-v).

OBJECTIVES • Brand establishment.

• Exploration and optimization.

• Demographic dividend.

• Opportunity cost.

FLOW OF FUNDS SPONSORSHIPS • POTENTIAL • PART • MONETARY

EMI

WORKSHOP

CONTINGENGY

fUNDS

ALLOCATION OF FUNDS

• Lathe Machine • Shaper Machine • CNC Milling • Milling Machine • Cylindrical Grinding • Surface Grinding • Drilling Machine • TIG Welding • MIG Welding • Gas Welding • Electric Arc Welding • Universal Testing Machine

College Facilities

VEHICLE OVERVIEW

Part Specification

Overall Length 2640 mm

Height 1320 mm

Wheelbase 1600 mm

Track Width 1300 mm

Centre of Gravity Height 250 mm

Ground Clearance 89 mm

Engine Honda CBR 250R

Engine Displacement 249.6 cc

Engine Power 25 bhp

Transmission 6 speed Constant Mesh

Suspension Double A Arms Pushrod

Brakes 4 Wheel Disc Brakes