The document summarizes the Baja SAE India 2014 team from Babu Banarasi Das National Institute of Technology & Management. It discusses the team size of 25 members and provides details on the vehicle specifications, subsystems, and manufacturing plans. Key aspects covered include the roll cage design using carbon steel, independent double wishbone suspension setup, rack and pinion steering, disc brakes, and Mahindra ALFA CVT transmission powered by a 305cc engine. The team's design validation, cost estimation, and manufacturing processes are also summarized.

1. BAJA SAE INDIA 2014
VIRTUAL ROUND
TEAM VIKRAM
Babu Banarasi Das National Institute
of Technology & Management
Lucknow , Uttar Pradesh
Northern Section

2. TEAM LEADER
DESIGN & ANALYSIS TEAM
Steering
Roll cage
Suspension
MANUFACTURING
TEAM FINANCE
Fabrication
Parts Procurement
Jigs & FixturesBrakes
Budgeting & Cost
Estimations
Market Survey
Marketing and PR
Transmission
Engine & Electricals
Modeling & Simulation
SPONSORSHIP
Ergonomics & Aesthetics
TEAM FORMULATION
TEAM SIZE :- 25 MEMBERS
Design Input by: BAJASAE 2014 Rulebook
Modelling on: PRO-E WILDFIRE 5.0
FEA Constraints formulation on : ANSYS 14.5 & ALTAIR HYPERWORKS

3. Technical Specifications
Parameter Value
Vehicle length 2500 mm
Vehicle width 1556.4 +00
+50 mm
Ground clearance 254 mm
Vehicle height 1534.25 mm
Roll cage material Carbon Steel
(AISI 1018)
Tube dimension 25.4 mm outer dia.
3mm inner dia.
Roll cage mass 22 kg
Total mass 350 kg approx.
Parameter Value
Battery 12V/44 Ah
Suspension
Front Rear
Double
Wishbone
Double
Wishbone
Damper mounting Lower
arm
Upper
arm
Max speed 58 km/h
Brake
Front Rear
Disc Disc
Steering Rack and pinion
Tyres 22 X 8 - 10

4. Roll Cage
Design Methodolgy:
• Driver oriented rollcage design.
• Light weight, compact and simple.
• Ease of egress during accident.
• Members are kept short by optimum
triangulation to have a good load transfer
path.
• Frame is designed to be stiff for loads like
bending and torsional.
• Material is kept farther from rotating axis
to increase stiffness.
• Polar moment of inertia is maximised.
Total number of weld joints: 48
Width of Rollcage: 750 mm
Length of Rollcage: 2500 mm
Height of Rollcage: 1280.25 mm
Material Used: Carbon Steel (AISI 1018)
• UTS: 365 Mpa
• Carbon content: 0.18%
• Outer Diameter: 25.4mm
• Wall Thickness: 3mm (primary members)
0.89mm(secondary members)

5. Devised Plan for Finite Element Analysis
INITIAL DESIGN FINAL DESIGN
CONSTRAINTS
REAR
CORNERS(ALL
DOF=0);
SUSPENSION
MOUNTINGS(Uy,
Uz=0)
OPPOSITE SIM
MEMBERS(ALL
DOF=0)
LFS MEMBERS
(ALL DOF=0)
FRONT
CORNERS(ALL
DOF=0);
SUSPENSION
MOUNTINGS(Uy,
Uz=0)
LOADS 5G 3G 2.5G 4G
TESTS FRONT IMPACT SIDE IMPACT ROLL OVER REAR IMPACT
FACTOR OF SAFETY: ALWAYS CONSIDERED FOR THIS DESIGN BETWEEN 1.5 - 4
CONSIDERATION FOR MESHING: Tria elements are considered below 5% for meshing.
Warpage below 7O . Jacobian ratio kept around 1. Aspect ratio is kept less than 7.

6. Steering
The steering system allows the driver to control
the direction of vehicle travel. This is made
possible by linkage that connects the steering
wheel to the steerable wheels and tires.
Types of steering:
1.Recirculating ball steering gear
2.Rack and pinion gear
3.Worm and Sector
We are using the Rack and Pinion gear
system.
Design selection criteria:
We are using the rack and pinion gear system just
because due to its low cost, its better compatibility
with our compact design and its simple
construction. We are using the manual steering
system, so it will help us for immediate response.
CALCULATIONS :
Wheel base - 1800mm
Track width - 1250mm
Lock to lock ratio - 3
Steering ratio - 16:1
Ideal Ackerman angle - 19.15
Actual Ackerman angle- 7.660
Inner angle(i) – 37.590
Outer angle(o)- 29.93o
Turning Radius- 2963mm
Caster- 5o negative
Camber- 2o positive

7. Braking System
• The brake system consists of four wheel disc
brakes actuated by two independent master
cylinders. The brake pedal uses a 6.2:1 pedal ratio
.
• The brake callipers chosen are single piston
floating type callipers of Honda Aviator and Bajaj
Pulsar220 .
• DOT 4 brake fluid will be used for braking
purpose
Specifications
Pedal ratio = 6.2:1
Pedal size = 7.75”
Braking percentage = 62:38
Master cylinder type: Two
random master cylinders of
Maruti 800 and a balance bar.
Brake lines: maruti 800 brake
lines and hoses
Calliper type: single piston
floating-type callipers of
Honda Aviator and Bajaj Pulsar
220
Calliper cup size = 1.5”
Rotor type: ventilated
Rotor size = 7.48”(190 mm )
Rotor thickness = 4mm

8. f = 7.84m/s2
Rf = 2121.45N and Rr = 1308.54N. this will be the front wheel and rear wheel reactions.
after a hard braking on level track, producing a deceleration of 6.87 m/s2
• STOPING DISTANCE
SPEED
(Km/Hr)
Stopping
Distance(m)
Braking
Time(s)
30 4.42 1.06
40 7.87 1.42
50 12.30 1.78
58 16.55 2.05

9. Ergonomics & Safety Features
Ergonomics refers to the relationship between people and their working
environment, so in our vehicle the perspective of ergonomics has been
considered over 4 points:
1. Vision
2. Ease of egress
3. Additional Controls

10. POWER TRAIN TRANSMISSION
Manual transmission needed gear shift which
would require some area near driver seat and thus
increases the dimension of buggy. So we decided
to go for cvt transmission.
Pulley based CVT is the most affordable and simple
one. It consist of two pulleys.primary pulley
connected to engine and secondary pulley
connected to axle.These two pulleys are connected
by a rubber V belt. Variation in the pitch radii of
these pulleys lead to the change in the gear ratio.
CVT Transmission option available :
1.Mahindra alfa cvt.
2.Polaris p90 cvt.
We are opting Mahindra ALFA
because of its well known coupling
with B&S Engine and its low cost.
Power train refers to the group of
components that generate power and
deliver it to the wheels of vehicle.
ENGINE SPECIFICATIONS
Torque 14.50 ft-lbs
Displacement 305
No. of cylinder Single
Configuration Horizontal
Technology OHV
Length 12.3 in
Width 15.4 in
Height 16.4 in
Weight 50.4 lbs
Bore 3.12 in
Stroke 2.4 in
Engine Fuel Gasoline
Spark Plug RC12YC

11. Suspension
Design Criteria:
Both the front and rear suspension system
are independent double wishbone(A-arm)
suspension having unequal control arms. It
is chosen because
1: Wishbone suspension give more
movement of the tires and hence the
vehicle.
2: In double A-arm suspension, force is
distributed at five points on the roll cage
unlike at only one point in macpherson
strut.
3: It can be slightly adjusted for different
parameters of suspension tuning like
chamber angle, ground clearance etc.
The A-arms at the front are pinned to the
roll cage while at the knuckle end the arms
are attached using boll and socket joints.
While at the rear as there is no cornering
requirement the A-arms are pinned both to
the roll cage as well as the knuckle.
FRONT LOWER CONTROL ARMS
LENGTH: 280 mm
REAR UPPER CONTROL ARMS
LENGTH: 190 mm

12. Design Validation Plan

13. DESIGN MODE AND FAILURE EFFECT ANALYSIS

14. COLLEGE FACILITIES
Centre lathe
Milling
Pipe bending
Electric arc welding
Oxy-Acetylene Welding
Drilling machine
Shaper machine
Power hack saw
Portable drilling machine
Planer Machine
35%
11%
2%
8%
7%
6%
2%
13%
16%
PIE CHART
ENGINE & DRIVE TRANSMISSION STEERING
SUSPENSION FRAME & BODY BRAKES
ELECTRICAL SAFETY MISCELLANEOUS
SUBSYSTEM MATERIALS EXTRAS TOTAL
ENGINE & DRIVE 70,000 - Rs. 70,000
TRANSMISSION 22,700 150 Rs. 22,850
STEERING 2,500 1,000 Rs. 3,500
SUSPENSION 11,000 4,500 Rs. 15,500
FRAME & BODY 9,000 5,000 Rs. 14,000
BRAKES 10,000 1,580 Rs. 11,580
ELECTRICAL 4,370 - Rs. 4,370
SAFETY EQUIPMENT 25,890 - Rs. 25,890
MISCELLANEOUS - - Rs. 33,500
TOTAL Rs. 2,01,190
Cost Estimation
Processes in sequence of:
 Pipe Cutting
 Bending
 Welding
 Inspection
 Undercoating
 Drawing
 Baking
 Painting
Then the roll cage is assembled
with:
1.TYRES, DAMPERS AND
SUSPENSION
2.ENGINE SYSTEM
3.STEERING AND BRAKES
4.DRIVER SEATPADDING
5.TRANSMISSION SYSTEM
MANUFACTURING PROCESSES REQUIRED