design stats of formula style car

1. Team Vega
Supra SAE INDIA Student Formula Team
JSS Academy of Technical Education, Noida

2. Team Formation

3. Ergonomics and Structure
Right Side View Top View
Front View

4. 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.

5. 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

6. 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.

7. 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

8. 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 .

9. Other parameters –
*Above parameters are at static condition.
Brake system
• Weight Transfer –

10. • 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 –

11. • 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

12. 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

13. 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)

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)

15. DFMEA & DVP

16. Project Management
Phase I
Design & Fabrication
July-November
End Semesters
(GAP)
December
Phase II
Design & Fabrication
January-March
Phase III
Testing & Optimization
April-June

17. Cost Plan

18. 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
WORKS
HOP
CONTINGE
NGY
fUNDS
ALLOCATION OF FUNDS

19. • 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

20. 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