FACULTY OF MECHANICAL ENGINEERINGUNIVERSITY OF TECHNOLOGY MARA

SHAH ALAM, SELANGOR

MEC532 MECHANICAL ENGINEERING DESIGN 2FINAL REPORT

PROJECT TITLE: DESIGN & FABRICATE A SINGLE SEATER VEHICLE

(CHASSIS)

TEAM LEADER : AHMAD HASSAN B MUHD MUHAYYIDIN SIGNATURE: (20133411786)

TEAM MEMBER : MOHAMAD HAZIM FAHMI BIN MOHD YAMIN SIGNATURE:

(2012226818)

TEAM MEMBER : MOHAMAD ZAID BIN MOHAMAD ZAILANI SIGNATURE: (2012241394)

TEAM MEMBER : MUHAMAD SHAFIQ BIN SAUFI SIGNATURE: (2012876726)

TEAM MEMBER : MOHAMAD FARIZ AIZAT BIN ABDAIN SIGNATURE: (2012223106)

TEAM MEMBER : KU SITI FATIMAH AZZAHRA’ BT KU MOKHTAR SIGNATURE:

(2012540029)

PROJECT ADVISORS: EN HAKIM ABDULLAH

ABSTRACT

This design project is the requirement for Part 6 students of Faculty of Mechanical

Engineering. Each class were required to build a single seated vehicle which comprises 7

departments from each class which are chassis department, safety department, bodywork

department, braking department, steering department, powertrain department and suspension

department.

We are from chassis department were required to build a strong and light chassis for

our single seated vehicle. Aspects of ergonomics, safety, ease of manufacture and reliability

are incorporated into the design specifications. Analysis are conducted on all major

components to optimized strength and rigidity, improve vehicle components and to reduce

complexity and manufacturing costs.

3D models have been made for analysis purpose by using CATIA software and

analysis has been made.3D assembly models of the single seated vehicle are designed for

understanding purpose. The design of chassis starts with the reviewing and drawbacks of

design 1 chassis structure and concludes with the changes made for this design 2.

ACKNOWLEDGEMENT

Apart from the effort of us, this design project was done successfully because of the

encouragement and guidelines from many others. We would like to take this valuable

opportunity to express our gratitude to the people who have been a big help to us during

completion of this project.

First and foremost, We would like to thank our supervisor, En Abdul Hakim Abdullah

who has supported us throughout this project with his patience and knowledge. Guidance by

him physically and mentally is very valuable. He inspired us greatly to work in this project.

His willingness to motivate us contributed tremendously to our project. All these are the vital

factors which drive us till the end.

Secondly, we would like to offer our sincerest gratitude to members from other

department who provide us useful opinions and suggestions along the implementation of this

project. Their support made us able to complete this project. They are always by our side

without tired and fail when they are needed. Beneficial advices are obtained from them.

On the other hand, we would like to take this opportunity to thank our family members

for supporting and encouraging us during the completion of this project. Our deepest gratitude

from the bottom of our heart for the support, encouragement and inspirations we obtained

during this project.

Last but not least, we would like to thank everybody who was important to the

successful realization of this design project as well as expressing our apology that we could

not mention personally one by one.

TABLE OF CONTENTS

i. ABSTRACTii. ACKNOWLEDGEMENTiii. TABLE OF CONTENTS

1. INRODUCTIONa. Background b. Objectivesc. Scope of Projectd. Project Planning

i. Organization & Management Teamii. Project Schedule

2. DESIGN REVIEW(Reevaluation, reselection & refinement of product & blue print)

a. Design Backgroundb. Product Modification c. Engineering Analysisd. Final Blue Print

3. MANUFACTURING PROCESSa. Fabrication b. Assembly

4. COSTING & MARKETINGa. Budget & Actual

i. Manpower ii. Materials

iii. Machining

5. DISCUSSION & CONCLUSION

REFERENCES & CITATIONS

APPENDIX

a. Approved Blue Printb. Minute of Meeting

INTRODUCTION

Chassis is the most important part of fabricating of single seated vehicle. Its department

plays a very important role because it is very related to other components of the vehicle. The

change in dimension and design of chassis will affect the designation of other component of

the vehicle. Chassis consists of an internal framework that supports a man-made object in its

construction and use.

Chassis serves as an aero device, both by directing air but also by supporting the

deflection of other aero components. The chassis also act as the driver's center of confidence.

If the driver does not feel safe, either due to weak impact zones or flexy suspension feedback,

he will not go fast. Arguably more importantly, he may be injured by an unsafe chassis.

Finally, the driver must be entirely comfortable.

A good chassis must have following characteristics :

• Be structurally sound in every way over the expected life of the vehicle and beyond.

This means nothing will ever break under normal conditions.

• Maintain the suspension mounting locations so that handling is safe and consistent

under high cornering and bump loads.

• Support the body panels and other passenger components so that everything feels

solid and has a long, reliable life.

• Protect the driver from external injuries.

For this project, we are going to build a single seated vehicle based on SAE car

formula. All specification will be based on SAE car formula.

OBJECTIVESWhile striving to achieve the major aims, this project design work will focus on

number of basic objectives which are :

1. To perform design and analysis of a single seated vehicle with all working

components.

2. To organize a race competition among the students.

3. To perform an aesthetic design on the vehicle consistent with the time now.

This chassis department having several objectives that would like to be accomplished:

a) Flaws present in design 1 must be removed or improved.

b) Designing a chassis that will be easily adaptable and adjustable.

c) Students will be able to learn to use CAD software such as CATIA and Solidworks.

SCOPE OF WORK

There are several structural requirement that need to be followed in fabrication of chassis :

1. Only structural space frame chassis type are allowed ( no monocoque type ).

2. The chassis must be made from structural steel or structural steel alloy tubing meeting

the ISO 4948 classifications and the ISO 4949 designations. Alloy steel having at least

one alloy element the mass content of which > 5% are forbidden.

3. The vehicle chassis must be equipped with an effective roll bar that extends 5cm

around the driver's helmet and also extends in width beyond the driver's shoulders

when seated in normal driving position.

4. A roll cage is an optional for the team to attach as a frame member of the chassis.

5. Any roll bar must be capable of withstanding a static load of 700 N (approximately

70kg ).

6. Driver visibility: The driver must have adequate visibility to the front and sides of the

car. With the driver seated in a normal driving position he/she must have a minimum

field of vision of 200 degrees (a minimum 100 degrees to either side of the driver).

The required visibility may be obtained by the driver turning his/head and/or use of

mirrors.

PROJECT PLANNING

TEAM MANAGEMENT

TEAM MEMBERS JOB DESCRIPTION

AHMAD HASSAN

Supervising team working process. Planning the schedule of design and

fabrication. Communicating with others department

for further changes. Fabrication task: Metal cutting and

welding.

MUHAMMAD HAZIM Identifying material and equipment used and availability.

Fabrication task: Measuring steel bar and welding.

MOHAMAD FARIZ AIZAT Surveying and buying metal bar and bracket.

Fabrication task: Measuring and metal cutting.

MOHAMAD ZAID Drafting the final design for endorsement.

Communicate with other department for installing sub-system.

Fabrication task: Metal cutting and welding.

MUHAMMAD SYAFIQ Redrawing the design plan using CATIA, update the latest changes in chassis and other department.

Fabrication task: Measuring and metal cutting.

KU SITI FATIMAH AZZAHRA’ Managing fund for chassis department. Handling minutes of meeting and

drafting. Fabrication task: Metal cutting and

welding.

DESIGN REVIEW

DESIGN BACKGROUND

DESIGN 1

From the figure above, all the modification in design 1 has been done. However, on

the front roll bar the height need to be increase to provide space for steering department to

place their steering, and the shaft needed for the system. As the front roll bar is increase the

back roll bar must also increase in order to fulfill requirement by faculty that the effective roll

bar must extend 50mm around the driver helmet.

DESIGN 2

The figure above shows the final improvement that we made. Two long beams is

added on the base of the chassis to support the power engine at the rear. Front chassis will

support the steering, braking and suspension system. On the front side, few vertical beams is

added to enable shaft placement of suspension and the same time avoid force deformation

acting from vertical. Supports are also added at the rear to help in supporting the back roll bar

and the engine cage.

Figure: Final design

PRODUCT MODIFICATION

ENGINEERING ANALYSIS

(i)

(ii)(i) Back crash test Von Mises Stress (ii) Translational displacement

(i)

(ii)(i) Front crash test Von Mises Stress (ii) Translational displacement

(i)

(ii)

(i)Front roll bar test Von Mises Stress (ii) Translational displacement

(i)

(ii)(i)Roll bar test Von Mises Stress (ii) Translational displacement

(i)

(ii)(i) Side crash test Von Mises Stress (ii) Translational displacement

(i)

(ii)

(ii) Torsion test Von Mises Stress (ii) Translational displacement

FINAL BLUE PRINT

MANUFACTURING PROCCESS

MATERIAL SELECTION

FABRICATION AND ASSEMBLY

Width : 2.5 cm

Length: 2.5 cm

Thickness:1.5 mm

Conventional metal cutting machine is used to cutting the beam into desired length.

Tolerance must be counted

Gas Metal Arc Welding(GMAW) equipment is

used for joining of the beam. The shielding gas used is carbon dioxide gas

Chassis frame

COSTING

The budget that is given for our department is RM100.00.To be noted that all the parts are provided by the faculty. Some of the parts need to be

bought at outside of the faculty due to fulfill the design of the chassis. The equipment that we used also provided by faculty plus we used our own man power thus no cost is required.All major parts which is the base of the chassis and the upper support are ready available at the faculty. Some of the overhead cost must be considered to meet the requirement of the design.Here is the cost involves in ordered to complete chassis space frame:

No Component Quantity Sources Material Price per unit (RM)

Total price

01 Base length side bar 2090

2 Buy Steel 10.40 20.80

02 Base length center bar

2040

2 Buy Steel 10.10 20.20

03 Base width side bar 130

12 Buy Steel 0.70 8.40

04 Base width center bar

150

6 Buy Steel - 0

05 Front roll bar 1080

1 Buy Steel - 0

06 Back roll bar2500

1 Buy steel 12.40 12.40

07 Back roll bar support 1000

2 Buy Steel 5.00 10.00

08 Back roll bar engine

support 805

2 Buy Steel 4.00 8.00

09 Front roll bar support 666

2 Available Steel - 0

10 Upper front Side 682

2 Available Steel - 0

11 Upper back side 662

2 Available Steel - 0

12 Front & back central 460

5 Available Steel - 0

13 Vertical short bar 270

12 Available Steel - 0

14 Mounting bracket upper

16 Fabricate Steel - 0

15 Paint 1 Buy 10.40 10.40

TOTAL RM 90

DISCUSSION

From our progress in fabricating the chassis, we have certain limitation in developing

the chassis frame. In designing we use CATIA software but it is still new for us. We are

having hard time to study about this CATIA software with ourselves without further guide

from expert. We have to explore functional of all methods in software that works with

experiment samples and that take long time to master the CATIA software skill. Besides, we

also lack of handcraft skill, specifically in welding so we have to develop the chassis frame

based on our ability. We lack of workshop practice which result in lacking in the knowledge

to develop and built the chassis. However, we are successfully build the chassis

We also consider the cost because we have limited budget which we cannot afford to

exceed the budget and have to create our chassis which our very own skills and the tools that

are provided by the faculty. Even though, we lack of skill, we cannot afford to hire someone

to craft our chassis. Therefore we have to be a quick learner and craft our very own chassis.

Since we are limiting the cost, we cannot afford to buy fine material such as titanium. Hence,

we have to use the alternative ways by using the materials provided that is hollow rectangular

mild steel.

Next is limitation due to technical specification, we are only limited to structural space

frame chassis type only. Therefore we cannot create monocoque type chassis. From the

technical specification, we are not allowed to use any alloy steel having at least one alloy

element the mass contain of more or equal to 5%. Due to safety regulation, our chassis must

also equipped with an effective roll bar that extend 50mm around the drive’s helmet and must

be capable of withstanding a static load of 700N which applied in a vertical, horizontal or

perpendicular direction without deforming and also extend in width beyond the drive’s

shoulders when seated in normal driving position. The technical specification also limiting us

from exceeding the minimum wheel base of 1000mm and 1500mm maximum. Our vehicle

also limited by length and width of 2500mm and 1400mm respectively. Hence, because of

this specification, our department must also provide space for other department to install their

component without The design on chassis that been used are

For all part in chassis, we are using mild steel that meet the ISO standards which

available at Faculty of Mechanical Engineering, UiTM. The distance between helmet and roll

bar is 7cm. The width of chassis is 400.8 cm which is met the requirement. An analysis for

impact when load applying on roll bar had been conducted with static load 700N. our action

taken in design 2 of our chassis had been improved from design 1 which the viewing angle is

too low. Side mirror also had been attached for side viewing for driver's safety

CONCLUSION

The objectives of this project had been successfully obtained. All

design and analysis for chassis component had been conducted properly.

The designated chassis also has followed the requirement and also SAE

formula car. The modification that had been made from design before is

successful and had been proved on race competition at Mechanical Design

Day. This project also all students have increased soft skills such as

leadership, teamwork and spirit during accomplishment

REFERENCES

1. American Welding Society (2004). Welding Handbook, Welding Processes,

Part 1. Miami: American Welding Society.

2. Anders, A. (2003). "Tracking down the origin of arc plasma science-II. Early

continuous discharges". IEEE Transactions on Plasma Science

3. Craig, Ed (1991). Gas Metal Arc & Flux Cored Welding Parameters. Chicago:

Weldtrain.

4. Cary, Howard B.; Helzer, Scott C. (2005). Modern Welding Technology.

Upper Saddle River, New Jersey: Pearson Education.

5. Kalpakjian, Serope; Schmid, Steven R. (2001). Manufacturing Engineering

and Technology. Prentice Hall.

6. Lincoln Electric (1994). The Procedure Handbook of Arc Welding. Cleveland:

Lincoln Electric.

7. Minnick, William H. (2007). Gas Metal Arc Welding Handbook Textbook.

Tinley Park: Goodheart-Willcox.

8. http://www.mechanicalengineeringblog.com/tag/conventional-frame/

9. http://bieap.gov.in/Pdf/automobilechasis.pdf

10. http://www.colorado.edu/MCEN/MCEN4173/chap_01.pdf

11. http://www.learnengineering.org/2012/12/what-is-von-mises-stress.html

12. http://en.wikipedia.org/wiki/Finite_element_method

APPENDIX