IIT JODHPUR

Lesson’s Learnt:
Vehicle Performance in last BAJA event Suspension and Steering
1. Need improvement in brake assembly system 1. Stiff and light arms and joints should be
2. Change in tire alignment and consistent wheel preferred
wobbling 2. Accuracy in manufacturing to avoid play
3. Failure of steering tie rod, need of better 3. Avoid toggle position in steering mechanism
analysis 4. Proper clearance to avoid hindrance to
4. Poor knuckle manufacturing lead to imbalanced shockers
turning 5. Proper clearance between rear suspension
5. Rear tire slipping while turning arms and CV axle required

Braking
1. Stiff and light arms and joints should be
preferred
2. Accuracy in manufacturing to avoid play
3. Avoid toggle position in steering mechanism
4. Proper clearance to avoid hindrance to
shockers
5. Proper clearance between rear suspension
arms and CV axle required
Roll Cage Powertrain
1. Excessive head clearance is not required 1. Tuning of CVT affects vehicle performance,
2. Excessive clearance between fire wall and must be done accurately
engine assembly 2. Improper calculation of gear ratio lead to loss
3. Roll cage to be made flexible of traction
4. Optimization in members 3. Non-compliance of CV axle at high articulation
angles
4. CVT heats up, need of a mechanism to cool it
down
5. Gearbox heating causing high pressure built up
in it, thus resulting in leakage of oil
6. Improper assembly with other subsystems
 Comparative Analysis
   Parameter Old vehicle New vehicle Parameter Old Vehicle New Vehicle
Length​ 77’’ 77” Maximum 7.355 KW (10
7.355 KW (10 HP)
Width​ 58”  56'' Power HP)
56”​ Maximum
Height​ 55.8” Torque 19.66 N-m 19.66 N-m
Wheelbase​ 57” 55'' CVT (CVTech),
Track Width 52” ratio 0.43:1 to CVT (CVTech),
50''
(front)​ 3:1 ratio 0.43:1 to
Track Width (rear)​ 46” 48'' Transmission Custom 3.0:1

Performance specifications
Gearbox, Custom Gearbox,
Design ​ Ground Clearance​ 11”  12''
Reduction Reduction 8.89:1
Kerb Weight​ 161 kg 150 kg
11.6:1
Weight 46.0 : 54.0  (F:R)​  42.0 : 58.0 (F:R) Maximum
Acceleration 6.8 m/s 5.37 m/s2
2
Distribution​
17.01” (height) 17.87” (height) Top Speed 54.9 kmph 56 kmph
Technical Specifications

COG Coordinates​ 30.75”( front axle) 31.9”( front axle) Gradeability 64.90% 64.9%
26.25”(rear axle)​ 23.1”(rear axle)​ 
22”x8”-10” Front; 22”x8”-10” Front;
Tyre Size​ 22”x8”-10” Rear​​ 22”x8”-10” Rear​​ 
Independent,
Front Suspension​ Double Wishbone Independent,
Double Wishbone​
Power to
Suspension Rear Suspension​ Independent, Independent, Weight Ratio 32.42 W/kg 33.89 W/kg
& Steering ​ H – Frame Lower​ H – Frame Lower
Steering Type​ Rack & Pinion​ Rack & Pinion Comparison
Turning Radius​ 106.30” (2.7m) 94.49"(2.4 m)​
Front​ Disc Brakes ​ Disc Brakes ​
Braking​
Rear​ Disc Brakes​ Disc Brakes​

BAJA 2017 BAJA 2018

Roll cage Design Process - Ergonomics
Design constraints| Application |Weight |Manufacturability |Safety |Aesthetics |Cost

• Optimised diagonal members

DESIGN PROCESS • Better orientation for suspension
mounting
Background research
• Flexible roll cage for better
Ideation handling and weight transfer

Brain storming ERGONOMICS

• Custom made seat and steering
Detailed Design wheel
Testing • Leg space and comfort ensured
using simulation software
Validation • Steering wheel at comfortable
position
Design Review • Placement of Driver controls
• RRH inclined at 6 degrees
• SAE Standards

• Benchmarking • Inputs from • Inputs from • Material selection

• Drawbacks in previous subsystems subsystems • CAD model with
vehicle • Design inputs from • Design iteration different tube
• Rulebook constraints analysis team • Common CAD model dimensions
• Ergonomics • Development of roll • Design release • FEA & optimisation
• Sketching and cage • Detailing from • Aesthetics
conceptualisation • Design iterations Manufacturing POV • Final assembly
CAE Basic Processes and its Applications
DESIGN PROCESS CES Edupack and Benchmarking • Driver tolerance levels
• Weldability • Chest acceleration & Femur load
Literature • Strength and stiffness • Benchmarked pulse models
• Carbon Content • Safe stopping distance
Material Selection
• Work energy principle
Mesh method & size • Crumple zone
Boundary conditions Material OD Thickness Bending Bending Weight Yield
(in) (mm) strength stiffness /meter Strength
Force values (Nm) (Nmm^2) (Mpa)
Design modifications AISI 4130 1.25 1.65 485.402 3631.45 1.22 435
AISI 1018 1 1 164.44 1170.824 0.59 365
AISI 1018 1 1.6 244.420 1743.422 0.92 365

Torsional stiffness in N-m/deg

• Conventional 980

Roll Over Side Impact Rear Impact Front Impact

5G, FOS 1.69 3.5G, FOS 1.98 6.5G, FOS 1.46 6.5G, FOS 2.57
Suspension Design – Front / Rear
DESIGN PROCESS • Reduce wheel assembly size using stub axle and stub knuckle
• Better weight transfer during cornering
Literature &
BenchMarking
CoG , Mass Transfer
calculations

Defining Constraints

Iteration of hard
points in Lotus

Geometry Design Front : Double

Wishbone Unsprung mass :
55.6 kg
Structural Analysis Rear : H – Frame
Lower Castor 10 deg
KPI 8 deg
Roll Gradient :
4.3 deg/g Scrub 0 cm
Radius

Specifica Wheel Roll Camber Toe Roll Stiffness Spring Motion Natural Ride Rate
tions Travel Center Change Change (kg-m/deg) Stiffness Ratio Frequency(Hz) (N/mm)
(N/mm)
Front 6 (Bump) 2in 4 (Bump) -2 109.2834 11.21 0.7 1.56 7.24
4(Droop)
Rear 5(Bump) 0 7 (Bump) 0 149.7987 18.8 0.7 1.43 12.36
3(Droop)
Braking
Material Thermal Stress Weight
Selection
Solid Disk
Analysis
Venting
Analysis Reduction Brake calculations
Weight Transfer % 56.8
DESIGN PROCESS
Force Distribution 68:32
Literature, Benchmarking
Friction Coefficient B/w Tyre  &  Road
Force distribution, Calculations = 0.7
B/w pad & disc =
Brake Circuit Design 0.45
Thermal
Parameter estimation Torque Required Front = 166 N-m
Brake disc Rear = 75 N-m
Rotor and Pedal: Design and
Material G. Cast Iron
Analysis Force Required by Front = 1137/2 N
Max Temp 310 Caliper Rear = 512 N

Min. Temp 158 Master Cylinder 2.3 Mpa

Pressure
Braking Specifications
Disc Diameter Front  = 170 mm
FEA Split type F/R Rear = 200 mm
Brake pedal properties Brake Bosch Tandem
Master Stroke- 25.4mm
Material Aluminium cylinder Bore Diameter-
19.05mm Brake calculations
Applied Load 300 N Stopping Distance 8.8+9.1=17.9m
Brake type Disc Brake
Max. Stress 223.1 Mpa Brake Apache RTR 180 Stopping Time 0.8+1.6=2.4
calliper
Max Deformation 1.23 mm Pedal Specification Ratio=4.5:1
Brake pad Semi-metallic Apache Travel=127 mm
FOS 1.89 RTR 180 Force = 150 N
Brake fluid DOT4
Steering & Wheel Geometry
Specifications
DESIGN PROCESS Turning Radius 2.
(metres)
Literature & Benchmarking
FRONT: Motor cross ATV Tire
Fixation of Wheel base, track width • Extended surface and tread Rack Travel(cm) 7
pattern
Rack travel and steering arm length Pinion dia. 26.6
• Ideal for all terrain types
(mm)
Steering force calculation • Specialised tread compound
improves traction
Steering Ratio 122.76
Under steer -0.00285
Gradient (over steer)
REAR: Mud ATV tires
• Angled knobs dig into Steering angle Inner -45.00
terrain for maximum (degrees) Outer-28.3
traction.
Steering 8.24
• Use under a wide range of Torque(Nm)
conditions.
Ackermann 50%
Percent (%)
FRONT REAR
Steering 30
Wheel Tubeless tires column
geometry Angle(degree)
Front tire 21.5*7.2-10
Steering Wheel 5/6 turns lock
to lock
Rear tire 22*8-10 Detachable
steering wheel
Power Train
Design
Design constraints|
constraints| Application
Application |Weight
|Weight |Manufacturability
|Manufacturability |Safety
|Safety |Aesthetics
|Aesthetics |Cost
|Cost

DESIGN PROCESS Vehicle Performance

Literature study and Benchmarking Acceleration 5.37 m2/s
Deciding vehicle parameters Grade-ability 64.9%

CVT selection Top Speed 56 Kmph

Power to Weight 33.89 W/Kg
Calculation
Gearbox design
Validation ENGINE

Design Review Max. Power 10 HP at 3600

Max. Torque 19.66Nm at

2800rpm

• Flat assembly Transmission Type

• Use of DAQ system to tune the CVT. Constant Velocity CV-Tech CVT
• Use of a exhaust manifold Transmission (Gear ratio
• Optimized gear ratio as compared to last (CVT) 0.43:1 to
year 3.0:1)
• Use of modified Half-shaft.
• Usage of Cylindrical dampers Coupled with a Gear Ratio
single gear 8.89:1
• Use of custom gearbox reduction custom
• No differential used to overcome gearbox
shortcomings of open differential
 Cost & Weight Analysis 11
Sr no. Particulars Cost( INR)
Cost-Histogram 1 Engine (Briggs and Stratton)
2 Transmission
65477
100000 71500
  CVT 39500
80000   Gearbox 25000
  CV axles 7000
60000 3 Roll cage 17500
40000   Material 12500
  Welding 5000
20000 4 Steering 23400
  Rack & pinion assembly 15400
0   Steering column + Wheel 2500
n e g s y s s
i ne sio cag r in i m sion kes fet ical eat ngs eou   Wheel hub 4000
g is ll Stee es+R pen Bra Sa ctr S nti llan
En sm o s l e ou   Tie rod assembly 1500
R r
an Ty Su E M isce
Tr M
5 Tyres+Rims 65000
BAJA 2017 BAJA 2018 6 Suspension 81600
  Shockers fox float 3.0 61000
  Bushing,heim joint 4600
  Knuckles 16000
7 Brakes 12900
  Custom brake disc 2400
  Calliper assembly 9000
  Tandem master cylinder 1500
8 Safety 31950
9 Electricals 1000
10 Seat 1500
11 Mountings and fasteners 4000
12 Miscellaneous 1500
  GRAND TOTAL 377327
 DFMEA
SUBSYSTEM COMPONENT PFM S EFFECT OF FAILURE O POTENTIAL CAUSES OF FAILURE D RECOMMENDED RPN VALIDATION
ACTION
Frame Rollcage Deform 6 Structure damage 6 Excessive load, improper manufacturing 4 Replacer deformed 144 FEA of forces impacting
member
  Mountings Deform 7 Failure in functioning 7 Improper manufacturing, Excessive loading 5 Replace 245 Static FEA
of attached
components
Steering Tie Rod Bend 7 Permanent changed 5 Excessive stress experienced 6 Replace 210 Bump Steer, end play test
toe angle
  Heim Joint Break 10 Steering control is lost 6 Excessive loading, improper manufacturing, 6 Replace 360 Pre-run tests
Jerk due to larger bump

Suspension Arms Bend 7 Tyre misalignment 4 Excessive load due to Bump, Welding 5 Repair 140 Bump Test and FEA
deformation, improper manufacturing
  Bushings Deforma 5 Restriction of motion 7 Uneven dynamic load distribution, Bad 4 Replace 140 Track runs on rough
tion quality terrains
Wheel Hub Hub Axial 10 Wheel instability 3 Absence of proper fitting with knuckle/ 10 Restraining knuckle 300 FEA of forces/ conditions
assembly moveme improper manufacturing of hub and hub properly/ after test runs
nt/Break Replace
  Knuckle Break 8 Change in tyre 5 Improper Designing, excessive loading 8 Replace 320 FEA of forces acting
alignment, Dynamic
unstability
Transmission CV-axle Damaged 8 Vehicle failure 6 Excessive load 7 Welding/Replacing 336 FEA of CV axle
axle CV axle
  Gear Box Worn out 6 Hampered Vehicle 4 Manufacturing defect 10 Replace Gears 240 Dry Run Test
performance
Braking Brake disc Wearing 7 Degraded breaking 5 Manufacturing defect, insufficient 7 Replace 245 Break Dynamic test
of disc, force resistance of material to indentation
cracks
  Caliper Deform   Wearing of disc   Improper design, Manufacturing defect   Replace the mount   FEA of forces acting
mount(Rear) brakes, engine
efficiency reduced
Engine Air Filter Blocked 7 Absence of air in 5 Filter getting jammed by dirt/mud 6 Clean/Replace 210 Check after run
filter engine
  Piston Piston 8 Inability to start the 2 Engine oil runs out 9 Engine Servicing 144 Engine testing: Start/Stop
Cylinder Seizure engine cycle
Electrical Electrical Cut, 8 Failure in functioning 6 Sudden axial stress or shear force 8 Rejoin the wires if 384 Circuit testing
wires Short of electrical experienced broken/ Replace
circuiting components
 14
Team Composition with work allocation,College Manufacturing Facilities
Faculty Captain Vice- Vice- Marketing Design & FEA Suspension & Braking Power Train Materials and
advisor Captain Capatin Steering Manufacturing
• Overlook Distributing Overlook Paper Approach Rollcage , Suspension Brake Ckt CVT Performing
team work financial work potential wheel geometry design selection material
Deciding issues Ensuring companies assembly , Shocker Brake disc Gearbox selection
functioning timelines and Financial deadlines willing to Suspension selection manufacturing design, process
• Final ensuring they planning are being sponsor arms design Steering Pedal manufacture Overlooks
design are being and followed project in FEA and Geometry manufacturing Engine special
Approval followed budget Take part or in optimization Wheel selection mount manufacturing
Solver in case of making regular cash design and of certain parts
conflicts Banking feedback Powertrain
Design sub team and record s assembly
keeping

Dr. Karthik Krishna Sanket Divyanshu Poojan Vivek Singh Ritwik Sharan Aniket,
Kaushal Mohan Goyal Nakka ,Gautam, Pranav Somesh, Ankit Nitish , Parth Joshi,
Desai Sachin Preshit Mukul Mukesh Ashutosh Sudhir
Dr. Pravsh Saini Nitesh Rai Vishal Jain Shubham
Anand
Plapally

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