saeacmeracingbrochure

BAJA SAE?•SOCIETY OF AUTOMOTIVE ENGINEERS’ BAJA

•INTER COLLEGIATE OFF-ROAD VEHICLE DESIGN COMPLETION

ORIGINATED AT THE UNIVERSITY OF CAROLINA, 1976

•BIGGEST OFF-ROAD VEHICLE COMPETITION IN THE WORLD

•UNDERTAKEN IN INDIA SINCE 2008 AT NATRAX, PITHAMPUR,

MADHYA PRADESH

ABOUT BAJA SAE INDIA• BAJA SAEINDIA, A NATIONAL LEVEL EVENT THAT DEALS WITH THE DESIGN, ANALYSIS, MANUFACTURING AND TEST OF

AN OFF-ROAD ALL-TERRAIN VEHICLE. CONDUCTED UNDER THE LABEL OF SOCIETY OF AUTOMOTIVE ENGINEERS, INDIA.

TEAMS OF UNDERGRADUATES REPRESENTING VARIOUS INSTITUTES IN INDIA PARTICIPATE IN HUGE NUMBERS.

• IN THE INTERNATIONAL SCENARIO, SO AS TO ENHANCE THE QUALITY OF INDIAN STUDENTS IN TERMS OF PRACTICAL

KNOWLEDGE AND APPLICATIONS OF FUNDAMENTALS, BAJA SAEINDIA WAS UNDERTAKEN IN THE YEAR 2008 IN

PITHAMPUR, MADHYA PRADESH. SINCE THEN, WITH AN ENORMOUS GROWTH IN THE STUDENTS’ PARTICIPATION BAJA

SAEINDIA HAS BECOME A CORNERSTONE IN THE BAJA HISTORY. BAJA SAEINDIA IS SOON EXPECTED TO TURN INTO AN

INTERNATIONAL LEVEL EVENT

• BAJA SAEINDIA IS A TWO-FOLD EVENT, WITH BAJA SAEINDIA VIRTUALS AND BAJA SAEINDIA MAIN AS ITS PRE-QUALIFIER

AND FINAL ROUNDS RESPECTIVELY. BAJA SAEINDIA VIRTUALS IS A COMPLETE VEHICLE DESIGN PRESENTATION

COMPLETION WHERE IN THE TEAMS ARE REQUIRED TO PRESENT THEIR DETAILED VEHICLE DESIGN CONSISTING OF

ENTIRE VEHICLE DYNAMICS AND OTHER FIELDS LINKED WITH THE EVENT. TEAMS QUALIFYING THIS ROUND BUILD THEIR

PROPOSED MODEL WITHIN A GIVEN DEADLINE AND PARTICIPATE IN THE STATIC AND DYNAMIC RACE EVENTS IN THE

MAIN ROUND.

BAJA SAEINDIA BRIEFING

2008

2009

2010

2011

2012

2013

137 teams registered…56 selected






•SOCIETY OF AUTOMOTIVE ENGINEERS’ ASSOCIATION OF CANARA

MECHANICAL ENGINEERS

•FOUNDED IN YEAR 2013 AFTER THE CANARA SAE CLUB INAUGURATION

•25 BLENDED MIX OF UNDER-GRADUATE STUDENTS, 1 FACULTY

ADVISOR

VEHICLE TARGET SPECIFICATIONS

ROLL CAGE

Driver safety & comfort

Rulebook constraints

Robust + Unique

Light Weight

Economic Material – AISI 1020 (0.2 % carbon)

– Density – 7.89 × 103 kg/m3

– Yield Strength – 483 N/mm2

– Tensile Strength – 552 N/mm2

Only 35 weld joints !!!

58.7866 kgs

Rs. 10,546 + weld

cost

ANALYSIS + FINALIZATION• Keep the driver alive at 7.9g frontal

impact

• Keep the driver alive at 7.9g side

impact

• Keep the driver alive at 7.9g roll over

loading

• Maintain a factor of safety of at least

1.5

• Keep the modal frequency less than 10

Hz for an idling frequency of 30 Hz

9 iterationsFinal roll cage weight – 58.7866 kgs

Software used – Ansys 11.0

Test Maximum stress

(MPa)

Maximum

displacement (mm)

Severe Light Severe Light

Frontal

Impact

209.916 50.899 19.199 4.482

Left Side

Impact

212.877 36.281 11.241 2.119

Right Side

Impact

214.526 25.405 11.244 2.089

Rollover 196.1 26.176 3.36 0.6882

2.3 2.2689 2.2515 2.4630

HANDLINGac / gx = P / V · W

GEAR WF (N) WR(N)

1 249.7099 2693.2901

2 553.6718 2409.3282

3 737.7048 2205.2952

4 829.5539 2113.4466

R -337.2936 3280.2936

Wfs = 1015.04 N Wrs = 1927.96 N

Steady State Cornering

Rotation about C.G. Rotation about turn

Load Transfer Tires

Fy = Cα ⋅α

Load Inflation Pressure

Inner to outer

Cornering

Braking

Rear to front

Acceleration

Front to rear

Static Stability Factor (SSH) = T / 2H

Which, < µ, roll over is likely to happen

57 / (2 * 30.741) = 0.9271 > µ (= 0.65)

BRAKING

Mechanical

to Heat

Stop within a

safe distance

18.3025 m

2.396 sec

At 55kmph

an d µ = 0.65

STEERINGType Rack and

Pinion

Model Maruti Alto

Steering

System

Steering Ratio 14:1

Max Turning

Radius

3.36 meters

Inner Lock Angle 29ᵒ

Outer Lock Angle 16ᵒ

Ackerman Lock

Angle

61.1ᵒCamber 0.5ᵒ to 2ᵒ

Caster 2ᵒ to 4ᵒ

Toe 3 mm to 5 mm

King-pin

inclination

7ᵒ to 8ᵒ

Roll center

moves with

suspension

travel

Keep the

migration low

Keep it close to

C.G.

SUSPENSIONS

POWERTRAIN

Gear Gear

Ratio

Speed

(kmph)

Gradeability

1 4.6 13.3339 45.459ᵒ

2 2.773 22.1189 41.2215ᵒ

3 1.667 36.7941 38.7461ᵒ

4 1.115 55 37.5336ᵒ

R 8.128 7.5462 N / A

WEIGHTComponent Weight (kg)

Roll Cage 60

Engine 25

Transmission 35

Tires 30

Suspensions 20

Brakes 10

Steering 5

Body & Electricals 10

Driver 115

TOTAL 310

Briggs & Stratton 10 HP OHV Engine:

3800 rpm

305 cc

max 60 kmph

Mahindra & Mahindra Alfa Transmission

4 + R manual configuration

Torque 21 N-m at 3600 rpm

Reduction gear ratio 4.85

Tires

25” × 8” – 12” tires

12” × 8” – 4/114.3 mm lug rims

ERGONOMICS

VALIDATION PLANTask Validate by

Roll Cage Dimensions Check Measuring tape and protractor

Weight Check Weighing bridge methodology

Ground Clearance Measuring tape

Weld Check Destructive test

Engine test Engine Spec Test Heat balance sheet analysis

Leak Test Engine run and check for oil

droplets

Exhaust Check Smoke test to find % NOx and

CO

Transmission Check Check gradeability and speed

against calculated ones

Braking Check Stopping distances and stopping

times consistency and

proportioning valve check

Steering Check Turning radius measurement

Suspension Check Set suitable camber, caster and

toe values

Electrical Check Potential difference check by

multimeters

Visibility Check Ride in dark with headlights

Stability and Cornering Check Ride on unbanked areas

PROJECT PLAN

COST REPORTPARTICULARS COST

REGISTRATION & ENGINE Rs.1,00,000

ROLLCAGE Rs. 50,000

TRANSMISSION Rs. 50,000

TIRES Rs. 50,000

BRAKING & STEERING SYSTEM Rs. 35,000

SUSPENSION Rs.1,50,000

DRIVER SAFETY & ELECTRICALS Rs. 45,000

LOGISTICS Rs.1,00,000

MISCELLANEOUS Rs. 20,000

TOTAL Rs.6,00,000

TEAM STRUCTURE

RESOURCESUniversal Lathe Machine

Universal Drilling Machine

Universal Milling Machine

Shaper Machine

CNC Milling Machine

Hardness testing Machines

Arc Welding

I C Engines Labs

Heat Transfer Labs

Solid Edge CAED work base

Ansys workbench

Fluent Simulation

Autodesk Falcon*

Autodesk 360*Kaizen in welding

to reduce the weld

cost !!!

VEHICLE VIEWS

OUR ACHIEVEMENTS• IN 2014, 327 INSTITUTES FROM ALL OVER THE COUNTRY PARTICIPATED IN THE VIRTUAL EVENT HELD AT BANGALORE ON JULY

2013. OUT OF THE TOTAL PARTICIPATING INSTITUTES, 125 TEAMS CLEARED THIS PRE-QUALIFIER ROUND. OUR INSTITUTE WAS ONE OF THE SELECTED TEAMS AND IS ALSO THE HIGHEST SCORER IN THE ENTIRE COUNTRY BEATING MANY OF PRESTIGIOUS NATIONAL COLLEGES.

• BEING IN ITS MAIDEN YEAR, OUR TEAM IS ONE OF THE 7 TEAMS SELECTED FROM KARNATAKA, WE COMPRISE OF 25 STUDENTS REPRESENTING VARIOUS DISCIPLINES VIZ. MECHANICAL ENGINEERING, ELECTRONICS AND COMMUNICATION ENGINEERING AND ELECTRICAL AND ELECTRONICS ENGINEERING.

• FETCHING THE HIGHEST SCORE IN THE PRE-QUALIFIER ROUND, THE TEAM’S VEHICLE DESIGN HAS A FEW HIGHLIGHTING FEATURES SUCH AS A LIGHT WEIGHT CHASSIS, LEAST NUMBER OF WELDED JOINTS SO AS TO KEEP THE VEHICLE DESIGN SIMPLE AND ROBUST, ULTRA-SAFE DESIGN BASED ON THE STANDARDS PROVIDED BY THE AMERICAN MOTOR VEHICLE INSURANCE COMPANY. THE PROPOSED COST OF THE VEHICLE LIES WITHIN RS 6.00 LAC. INCLUSIVE OF LOGISTICS EXPENSES .A SPLENDID PERFORMANCE IN THE PRE-QUALIFIER PLACES THE TEAM AMONGST THE BEST PARTICIPATING TEAMS IN THE COUNTRY AND ALSO PROVES THE TEAM’S POTENTIAL TO BE ONE AMONGST THE BEST TEAMS IN THE MAIN EVENT AS WELL. WE DESIRE THAT WE WILL BE PARTICIPATING IN THE INTERNATIONAL COMPETITION, WHICH WILL BE HOSTED IN INDIA IN THE YEAR 2015, WITH THE SUPPORT OF PHILANTHROPIST OF OUR PLACE. THIS ENDEAVOR OF THE TEAM WILL BE A HUGE SUCCESS WITH YOUR KIND HELP AND SUPPORT IN EVERY POSSIBLE WAY.

5 REASONS TO SUPPORT SAE ACME RACING1. OUR ENDEAVOR TO MAKE OUR SPONSORS HAPPY :GIVE PUBLICITY THROUGH LOGOS ON CAR, MERCHANDISE, BANNERS,

MEDIA PRESENTATIONS AT COLLEGES, MALLS AND ALL EVENTS WE CONDUCT/ATTEND THROUGH PRINT MEDIA, INTERNET, RADIO, ETC. YEARLONG PUBLICITY CAMPAIGN, UNLIKE COLLEGE FESTS; EXTENDABLE TO ONE YEAR; ON/OFF-CAMPUS PUBLICITY.

2. CREATE A CLASS OF ENTREPRENEUR: THE EXPERTS OF THE INDUSTRY WILL SELECT THE TEAM ONLY AFTER EVALUATION OF THE “DESIGN & CALCULATIONS” DONE BY THE STUDENTS. ON PASSING THIS TEST HE HAS TO MANUFACTURE, TEST, MARKET, RAISE FINANCE, BUILD HIS TEAM AND COMPETE FOR EXCELLENCE NATIONALLY & INTERNATIONALLY. WE REQUIRE FINANCE TO THE TUNE OF INR 6.00 LAKHS; YOU ARE ENCOURAGING TEAM SPIRIT….. WHO ARE WORKING WITH A TEAM OF 25 MEMBERS OF HETEROGENEOUS THOUGHTS TOWARDS A COMMON GOAL WITH ONENESS ….. THIS WILL INCULCATE THE TEAM SPIRIT AMONGST THE STUDENT.

3. SHAPING A PERFECT ENGINEER :ENGINEERING STUDENTS ARE CHALLENGED TO BUILD A COMPLETE PRODUCT, AN ALL TERRINE VEHICLE, ON THEIR OWN. THE SET OF PEOPLE WHO ARE INVOLVED IN SUCH EVENTS ARE AMONGST THE SMARTEST STUDENTS AND PROFESSIONALS. STUDENT’S WILL GET AN OPPORTUNITY TO PUT THEIR THEORETICAL KNOWLEDGE TO PRACTICAL ENDEAVOR, THEREBY PUT TO TEST THE THEORY, THEIR KNOWLEDGE, INTELLECT, ASPIRATIONS… THUS YOU WILL HELP TO BRING OUT A PERFECT ENGINEER.

4. TO INSTILL THE INNOVATIVE IDEAS: HE PRIMARY GOAL OF THE TEAM HAS ALWAYS BEEN TO GAIN KNOWLEDGE AND EXPERIENCE IN HANDLING REAL LIFE SITUATIONS. THE PROCESS OF TRANSFORMATION OF THEORY INTO PRACTICE INSTILL IN THE STUDENT THE INNOVATION IDEAS WHICH MAY LEAD TO ACCELERATION OF RESEARCH AND INNOVATION. ONCE IN A WHILE, WE ALSO CONDUCT WORKSHOPS AND ACTIVITIES SO AS TO SPREAD KNOWLEDGE AND ENCOURAGE INTEREST AMONGST OTHER COLLEGES AND SCHOOLS.

5. CAN FIND YOUR STUDENTS ON NATIONAL MAP AND INTERNATIONAL AS WELL :YOUR STUDENT WILL GET AN OPPORTUNITY TO PARTICIPATE IN NATIONAL AS WELL AS INTERNATIONAL EVENT, THUS YOUR PLACE WILL FIND A PLACE IN NATIONAL AS WELL AS IN INTERNATIONAL PLATFORM… ALSO BRING NAME & FAME TO YOUR PLACE.

AREA 1 - FRONT

AREA 2 - SIDES

AREA 3 - DRIVER REAR

SPONSOR HIGHLIGHTS

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