1. BEANT COLLEGE OF ENGINEERING
& TECHNOLOGY, GURDASPUR
(GOVT.)
TEAM ID : 16190

2. SPECIFICATION VALUES
Overall Length 2447.20mm
Overall width 1828.80mm
Front track width 1470 mm
Rear track width 1550 mm
Wheel base 1850 mm
Ground clearance 297 mm
Wheels- Front &
rear
22*12*7 & 22*12*10
inches
Maximum speed 55.6 km/hr
Maximum
acceleration
7.4 m/s²
Gradabilty % 86.5 %
Stopping distance 19.4 m (40 km/hr)
Kerb weight 190 kg
Ratio FAW & RAW 45:55
OVERALL VEHICLE DETAILS

3. Materials AISI 1018 AISI 4130 AISI 1020
Availability 4 3 2
Strength 3 4 4
Cost 4 2 3
Weight 3 4 4
Total 14 13 13
Material used AISI 1018
Yield strength 365 MPa
Tensile strength 440 MPa
Elongation 15%
Outer diameter 25.4 mm
Wall thickness 3 mm
Over all length 2083.6 mm
Max. width 718 mm
Weight 54 Kg
Material selection
Ergonomics Related to Cockpit :
• Cockpit is designed in such a way that
driver can exit within 5 seconds in an
emergency .
• RRH is given an angle of 15 deg. To give a
good sitting posture to the driver.
• Front bracing members are adjusted in a
such way to give a wider view of vision.
• Side impact members are designed to
protect the driver from external threats.
Carbon 0.18 %
Iron 98.8 %
Manganese 0.6 %
Sulphur 0.05 %
Chemical Composition :
Welding used for the manufacturing of the roll cage is MIG welding .
Due to its lesser cost and good strength .

4.  Front impact force - 24000 N (8.6G )
 Max. stress - 184 MPa
 Deformation - 3.227 mm
 Factor of safety – 1.98
Rear impact force - 24000 N (8.6G)
 Max stress -293 MPa
 Deformation – 3.06 mm
 Factor of safety - 1.24
Roll over force - 2774 N (1G )
Max stress – 157 MPa
 Deformation – 6.4 mm
Factor of safety - 2.32
Side impact force - 11928.2 N (4.3G)
 Max stress - 302 MPa
Deformation – 3.9 mm
Factor of safety - 1.21
Paramete
r
Case
I
Case
II
Case
III
Size of Mesh
(Units)
20 10 8
No. Of nodes 219584 434629 485534
No. of
Elements
133446 236481 253079
Max value of
Von-Misses
Stress (MPa)
225.62 285.89 290
Percentage
Error
52.27 29.31 1.8
So we have selected the mesh size = 8
Because its Percentage error is less than 5 %
after performing iteration .

5. SUSPENSION DESIGN
Type of Suspension (Front And Rear) - INWARD CONVERGING TRANSVERSE DOUBLE WISHBONE
CHARACTERSTICS FRONT REAR
GROUND CLEARANCE
(m)
.297 .315
ROLL CENTER HEIGHT
(m)
.231 .281
CAMBER (deg) -1.21 -1.50
CASTER (deg) 3.18 3.18
KPI (deg) 12.53 3.18
MOTION RATIO .8 .9
WHEEL RATE (N/mm) 9.645 15.612
SPRING STIFFNESS
(N/mm)
15.07 19.274
NATURAL FREQUENCY
(Hz)
2.41 2.46
RIDE FREQUENCY (Hz) 1.96 2.27
ROLL
STIFFNESS(Nm/deg)
202.54 327.15
CG Height (m) – .505
Scrub Radius (m)- .067
Sprung mass (kg) – 204
Unsprung mass (kg)- 76
Material Used – 4130
MAX . VON MISES STRESS-175Mpa
FOS-2.62
Material Used- 4130
MAX. VON MISES STRESS- 148Mpa
FOS- 3.1
Bump travel (front)- 7inch
Bump travel (rear)- 6inch
Droop travel (front)- 5inch
Droop travel (rear)- 4inch

6. BRAKES
 Disc Brakes
 X-split brake circuit with master cylinder of Maruti 800 Bosch tandem cylinder (OEM) having bore diameter ¾
Inch and piston area of 0.4393 sq. Inch.
 Discs of Maruti Zen is used for front wheels and TVS Apache RTR 180 is used for rear wheels and calliper of
respective discs are used.
 For Brake fluid DOT 3 is taken.
SPECIFICATIONS VALUE
FRONT DISC DIAMETER 182mm
REAR DISC DIAMETER 270mm
FRONT CALLIPER PISTON 50mm
REAR CALLIPER PISTON 32mm
BRAKE FORCE 2058N
PEDAL FORCE 70lbs
DECELERATION 7.35m/s²
PEDAL RATIO 6:1
FRONT BRAKING TORQUE 189.04Nm
REAR BRAKING TORQUE 280.36Nm
CALLIPER PAD FRICTION
COEFFICIENT(FRONT WHEEL)
0.08
CALLIPER PAD FRICTION
COEFFICIENT(REAR WHEEL)
0.29
SPECIFICATIONS VALUE
FRONT CLAMPING FORCE 12.86KN
REAR CLAMPING FORCE 3.548KN
CYLINDER PRESSURE 6.59MPa
MEAN BRAKING RADIUS 91.85mm
WEIGHT TRANSFER 552.814N
STOPPING DISTANCE 19.4m(40km/hr)
STOPPING TIME 1.75s(40km/hr)

7. STEERING SYSTEM
Over steer
Ackerman % - 80
Steering angle -
inside - 40.51 (deg.)
outside - 26.98 (deg.)
Turning circle radius – 2901.2mm
STEERING GEAR – R & P
 RHD (MARUTI SUZUKI 800)
Rack travel – 120mm
Turns lock to lock, rev. – 3.25
Steering ratio – 12:1
OBJ center distance - 110mm
Length of Tie rod – 397mm
Length of steer arm – 86.9 mm
STEERING COLUMN
Collapsible
Without power assist
LOTUS STEERING ANALYSIS
Steer Toe Ackerman Turning circle
Travel angle (%) radius
(mm) {SAE} (mm)
(deg.)
45.00 38.00 81.70 2979.55
30.00 22.70 71.53 4955.39
15.00 10.57 67.35 10418.21
0.00 0 66.16 0
-15.00 -9.62 67.35 10418.21
-30.00 -18.63 71.53 4955.39
-45.00 -27.25 81.70 2979.55
STEERING WHEEL
Steering wheel diameter -390mm
Steering wheel torque – 58.5Nm
Wheel Geometry

8. POWER TRAIN
• ENGINE SPECIFICATIONS
• Briggs and Stratton
• 305CC
• 10HP
• 19Nm at 2800 rpm
Overall
gear
ratios
Tractive
force
(N-m)
Maximum
velocity
km/hr
Maximum
acceleration
m/(sec) ²
Gradability
%age
37.5:1 2294 9.4 7.4 86.5
25:1 1529 13.5 4.7 57.6
12.5:1 764.6 28.2 2.0 28.8
6.25:1 382 55.6 0.6 14.4
• TCVT= 14.5 lb-ft * (12 in/ 1 ft) * (3/1) *
0.83 = 433 in-lb =48.9Nm
• Factor of safety for shaft is 4
• For tire diameter =22inch the maximum velocity attained by
vehicle is 55.6 km/hr
• N= Transmission efficiency = 0.85
• Torque on the wheel=420ft-lb = 569.4Nm
• 12.5:1 Gearbox is used
• TRANSMISSION : CVT COUPLED WITH MAHINDRA
ALPHA GEAR BOX
• LAYOUT OF ENGINE , CVT AND GEAR BOX

9. COST ANALYSIS & WEIGHT DISTRIBUTION
26.50%
20.50%
19%
6.30%
12.60%
15.14%
COST ANALYSIS
POWER
TRAIN
SUSPENSION
& STEERING
ROLL CAGE
BRAKING
WHEEL TIRE
SAE
REGISTRATI
ON
24.28%
19.28%
19.40%13.92%
23.00%
WEIGHT DISTRIBUTION
TRANSMISS
ION &
BRAKING
SUSPENSIO
N &
STEERING
ROLL CAGE
WHEEL &
TIRE
DRIVER

10. PROJECT PLANNING

11. Part Function Failure Models Precaution Validation Accomplishment
Roll Cage Basic Soul Of
Vehicle And To
Protect The
Driver
When Material
Reaches To
Ultimate Stress
Value.
Use Of AISI 1018 Steel
Having Yield Strength
Value Equal 370 Mpa.
Welding Test Universal Testing
Machine
ENGINE To Generate
Power
Spark Plug
Failure/Improper
Functioning Of Old
Filters.
Regular Check Of
Spark Plug & Filter
Change.
Fuel Leak
Test
Vehicle Should Be
Tested In Various
Road Condition
TRANSMIS-
SION
To Transmit
Power From
Engine To Wheels
Improper
Lubrication/Unexp
ected Load.
Use Of ISO Grade Oils
.
Speed And
Acceleration
Test
Road Test
SUSPENSION To Absorbs
Shocks And To
Give A Smooth
Drive
When Coil
Reaches To Solid
Length.
Proper Calculation
And Assumption In
Designing.
Wheel Travel Inch Tape
BRAKES To Reduce The
Speed When
Required And
Emergency Stop
Circuit Failure Due
To Leakage
Worn Out Break
Pads.
Bleeding Of Vehicle’s
Break Before Every
Run, Checking And
Replacement.
Breaking Test Road Test
WHEELS To Provide Good
Traction
Inappropriate Air
Pressure/Puncture
Tire.
Checking Of Air
Pressure At Every
Refuel Backup Extra.
Tire Air
Pressure
Air Pressure
Gauge
DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN

12. TEAM COMPOSITION & COLLEGE FACILITIES
TEAM STRATEGY FACULTY ADVISOR : SANDEEP GANDOTRA
DEPARTMENTS TEAM MEMBERS
1. ROLL CAGE ARSHDEEP SINGH, AMAN RANA,
VINAY KUMAR (Captain) ,LOVY
MINHAS, SAEED AKHTAR, SACHIN,
SATNAM SINGH
2. TRANSMISSION ANUJ BHARDWAJ, SHIVAM
BHARDWAJ,AMARJEET GULERIA,
NAVJEET SINGH, KASHISH
MAHAJAN, RAKESH ,SHAMSHER
SINGH,VARUN SHARMA
3. SUSPENSION ANSHUL SHARMA, ABHISHEK
THAKUR, VINAY KUMAR, ANUBHAV
MAHESHWARI, ABHINAV KUMAR,
NITISH PANDEY, SATISH
4. BRAKING GAGANDEEP SINGH, ANUJ
BHARDWAJ
5. STEERING AMAN RANA, ARSHDEEP SINGH,
AMARJEET GULERIA
6. DRAFTING &
ANALYSIS
KRISHNA KHOSLA,JATIN SARINE
7. MANAGEMENT ANUBHAV
MAHESHWARI,SHAMSHER
SINGH,UTKARSH
COLLEGE FACILITIES
 For Roll Cage , Each and every equipment
available in welding shop.
 For Custom Knuckle , requirements are
available in Carpentry , Foundry and machine
shop.
 For Seat Installation and Sheet Covering of
vehicle , equipments are available in welding
and sheet metal shop.
 For clamping of Wishbones , each and every
requirements are available in Central Workshop.
 For Assembly and Installation of all other parts
of vehicle, requirements are available in Central
Workshop.