Supra and Hackathon - Design Report
Supra and Hackathon - Design Report
MGM ACCELLORS
1
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
ABOUT SAE
SOCIETY OF AUTOMOTIVE ENGINEERING
• SAEINDIA is an affiliate society of SAE International, registered as an
Indian non profit engineering and scientific society dedicated to the
advancement of mobility community in India.
• SAEINDIA was formed in India in 1994-95 with Dr. Pawan Goenka,
appointed as advisor for India.
• Principal emphasis is placed on transport industries such as automotive,
aerospace, and commercial vehicles.
• In 2007 Baja SAEINDIA was launched which proved to be the growing
crop of engineers from colleges across the country to showcase their talent
and fuel the growth of the Indian automotive industry.
• In 2008, Formula SAEINDIA was launched with the name of SUPRA
SAEINDIA.
2
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
Event Stages
Static Events Includes:
• Marketing Presentation
• Engineering Design
• Cost Evaluation
• Skid-Pad Event
• Autocross Event
Endurance
The SUPRA SAEINDIA events consists a total of 1000 points distributed
evenly in the different static and dynamic events.
3
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2015 Team
Strengths:
1. Coordination
2. Chassis Design
3. Virtual round, static events
4. Paper work, accounts
Weakness:
1. Lack of guidance.
2. Unaware of location of brake light.
3. Incorrect mounting points for seat belts.
4. Change of location of catch tank.
5. Scheduling
6. Springs used for suspension has low stiffness due to which there was over
travel.
4
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2016 Team
2 Inspection Stickers Bagged
Strengths:
1. Experience
2. Proper design, fabrication & assembly of brake lights, mounting points for
seat belt.
3. Placement of components.
4. Good implementation of time management.
5. Software skills.
6. They had self-confidence and consolidating.
7. Team had a good overall technical progress
Weakness:
1. Improper calculations of brake test leading to failure in brake test.
2. Ground clearance was high as per requirements of SAE rules.
3. Improper design of steering mechanism.
4. Team faced economic problems while fabrication.
5. Improper maintenance of account and bills & Shortcomings in overall
presentation of the car.
6. Welding of components was not precise.
7. Mounting of brake hoses were tangled.
5
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2017 Team
Strengths:
1. Proper manual calculations of all engine components.
2. They overcome the Ground clearance than the previous team.
3. Team member had a good knowledge about mechanism used vehicle.
4. Team had maintained the accounts and bills.
5. This team had a good overall presentation in the event.
6. This team had a proper design and neat maintenance.
7. Reports were presented in proper manner.
Weakness:
1. Team lacked proper design of vehicle.
2. Team had faced problem due to utilization of old components from the
previous year vehicle.
3. Team had improper location for fuel tank.
4. Faced problems in suspension geometry.
6
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2018 Team
Strengths:
• Differential Design Was Proper.
• Business Report Was Properly Presented.
• Welding Of Chassis Was Good.
• Got Sufficient Sponsors To Built The Car.
• Primary Structure Of Chassis Was Accurate.
• Proper budget of 4,25,000 rupees were sanctioned and new standard parts
were procured.
• Proper presentation of cost report.
Weakness:
• Weight & length of the car was exceed.
• Some parts were not properly optimized in their weight like sprocket
design of chassis.
• Bleeding problems in callipers due to transportation from Mumbai to
Delhi.
• Wiring and chain was loose.
• ECU mounting was not proper.
• Fuel lines were not proper.
• Safety wire was not properly wounded on the callipers as per their design
rules.
• Design and machining of hubs and uprights gone wrong.
• Due to excess load axle was broken.
7
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2019 Team
Meet The
Team
8
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
DESIGN
FABRICATION
ASSEMBLY
DOCUMENTATIO
N
TESTING
OVERALL PLAN
9
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
DESIGN CONSIDERATIONS:
We have followed all rules as per SAE-INDIA SUPRA rulebook such as standard values of
track width and wheelbase, types of tubes used for fabricating a chassis with its dimensions,
tubing material etc.
DESIGN PARAMETERS:
Here we can take a look at following points which are mentioned below:
• Suspension system
• Brake system
• Steering system
• Design and installation of impact attenuator
• Roll cage
RESEARCH:
This phase includes entire methodology for making a racing car. Main objective of this
competition is to reduce the weight of the car so we have focussed on this aim to make a car of
minimum weight by modifying design several times.
COMPETITION PROJECTIONS:
SAEINDIA is an open platform where any Engg. college from India can participate to gain
knowledge regarding automobile, mechanical field.This competition generally schedules two
main events such as static and dynamic. Most important is technical inspection part which
comes under dynamic events where judges from several countries come together to check faults
in design and fabrication of car and give suggestions to overcome this difficulties. Also, last
but not least is endurance test where we are competing with other colleges by means of car
racing on track.
10
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
2. DESIGN
Design of chassis is done considering strength, weight reduction, driver’s safety and packaging
of all components. Also focus is given to grounding of vibrations of engine to suspension points
using proper triangulation & vibration isolators used to reduced vibrations.
3. MATERIAL USED
Material properties: Ultimate Tensile strength= 440 Mpa, Yield strength = 370 MPa
i. Front Impact
11
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
B. Engine
1. Engine Selection
For SUPRA 2018, we are using KTM DUKE 390.
Engine is the heart of vehicle. Optimum pumping of the heart defines engine
performance.
2. Specifications :
Layout Single cylinder , water cooled , 4 stroke
Capacity 373.3cc
Bore Diameter 89 mm (3.5 in.)
Stroke Length 60 mm (2.4 in.)
Compression Ratio 12.6:1
Injection System E.F.I/M.P.F.I
Power 43 bhp@9000
Torque 35Nm@7250
Rpm
3. Drive Train
To complete the caron time and keep the costs low we have decided to use the stock gear box. We
have used open-type differential as per availability and ease of use. The driving sprocket has 15
teeth and the driven sprocket has 52 teeth.
Driving sprocket 15
Driven Sprocket 52
Centre Distance 12.2inch
Chain Pitch 0.625 inch
No. Oflinks 131
Chain Length 866
12
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
4. Gear Ratio
5. Electronics:
• The instrument panel will be equipped with speedometer or meter console, tachometer, and
heat/oil indicator.
▪ All the readings will be driven from the Engine Control Unit. Brake lights of red colour would
be commissioned on the rear part of the vehicle as mentioned in the rulebook.
▪ Primary master switch would be installed on the right side of the vehicle, in proximity to the
Main Hoop, at shoulder height such that it can be easily actuated from outside the car.
▪ Cockpit master switch would be located on the instrument panel within easy reach of driver.
▪ Brake over travel switch is placed just after the brake pedal such that if the brake fails, the
switch would cut supply to ignition and fuel pump. Power for the components would be driven
from Exide Lead acid based battery pack.
According to Rulebook a restrictor of minimum diameter 20mm is to be used, hence, a plenum and
runner model have been designed to prevent engine under feed and maintain performance. The Plenum
and runner volume are roughly twice the volume of cylinder. The exhaust is self-constructed usin gold
bent pipes and muffler. As stated in Rulebook the sound from exhaust is sufficiently less than 110db.
C. Fuel Tank
The goals for newly designed and fabricated fuel tank are strength, space optimization and stability.
Hence, 2mm thick GI sheet has been used for utmost strength. Baffle plates have been in corporate to
prevent fuel froms plashing during cornering and trapezoidal structure is chosen for lower surface area
to volume ratio. A pressure relief valve is placed at the centre of filler cap to release any extra vapour
pressure developed in the tank. Fuel tank has been placed on right side of the engine.
13
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
is very low turbulence along the body, hence successful. Low resistance means greater
performance of car. The fabrication has been done keeping in mind the ease of quick mount
and removal of FRP.
E. BRAKES
The design criteria for the brake system are it must lockup all the wheels and comply with all
the rules. Also the system consists of four wheel disc brake actuated by master cylinder. The
brake pedal uses pedal ratio 7:1 to multiply the input force applied by the driver. Two separate
master cylinder network is used for front and rear tyres with 9inch disc brakes at all four wheels.
Master cylinder used is having bore diameter 19.05mm so that it meet all the requirements. The
brake calipers chosen can apply enough pressure on brake pads to lock up all four wheels as
required by the rules.
1. Calculations-
STATIC WEIGHT
CALCULATIONS
1) wf = % wf * wt/100= 0.4*350/100=140kg
Tif = Torque due to moment of
2 )wr = % wr * wt/100=0.6*350/100=210kg inertia
Dynamic force calculation
Fd = c.g*wt*Ax/L=190*10-3*350*24.116/(1730*10-3)
Fd = 927.0023N
Total normal loads on axle
Lf= Mg + Fd =140*9.81+927.002=2300.402N
Lr= Mg-Fd = 210*9.81-927.002=1133.0098N
Braking force on tyre
Fbf= Uroad*Lf/2= 0.5*2300.402/2=575.1005
Fbr= Uroad*Lr/2=0.5*1133.0098=283.2745
Total Braking Torque to overcome Tif= Torque due to moment of
inertia
Ttf= Fbf*Reff=575.1005*270*10-3=155.2771Nm
Ttr= Fbr*Reff=283.27*270*10-3=76.489Nm
Torque due to moment inertia
I for wheels
I = MR12+MR22/2=0.5*7.2(0.27^2+0.165^2)=0.36045
For 2 wheels (front)
14
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
I= 2*0.36045=0.7209kgm2
Tif =I*α= 0.7209* 89.318Nm
Similarly for rear wheels
Tir=64.38972Nm
Total braking torque to overcome on axle
Tbf = (2*Ttf)+ Tif= 2*155.2771+64.38972=374.9439Nm
Tbr = (2*Tfr)+Tir = 2*76.4829 +64.38972=217.355
Total torque acting on the entire torque
Tbf + Tbr= 874.945+217.355=592.2989
Pressure acting on the master cylinder outlet
Force exerted by average person on the pedal
F=500N
Pedal ratio=7:1
Therefore, Force transmitted to the master cylinder piston=pedal ration* force=7*500=3500N
Pressure acting on the single master cylinder=F/2A
A=2*π/ (4*19.052 ) = 6.139N/mm2
Now, P master= P calliper= 6.139N/mm2 (Pascal’s Law)
Fcp= Pcal*Apiston
Ap= Area of piston * No. of piston
𝜋 𝜋
= ∗ 𝑑2 = ∗ [ 25 ∗ 10−3 ]2 ∗ 4= 1.9634 *10−3
4 4
15
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
1479 >592.298
Hence we can apply breaks successfully.
F. SUSPENSION
1. Type of tyres used
Normal passenger vehicle’s radial tyres are used considering cost and market availability. Alloy
rims used to lowe run-sprung mass. Tyre size decided considering many factors. Low profile and wide
tyres are used to reduce spring effect and for more traction. Wearegoingwith13’’rims at the front as
well as rear for proper balance of the vehicle.
2. Suspension
We have decided to go with Independent double wishbone unequal unparallel suspension with
pull rod at front and rear. Suspension geometry is designed and analyzed in Optimum-G software.
Track width 1300 mm at front and 1350mm at rear chosen from our past experience and the length of
cv axel. Wider track at the front helps in diagonal weight transfer during cornering also helps to reduce
turning radius. Suspension is designed for minimum roll and maximum tyre contact with track during
cornering.
3. Suspension parameters:
A-arms:
A-arms are made using AISI1018 tubes of size 17mm OD X 4mm thickness tubes. Tapping is done to
fix rod end inside the tube. This material selected considering the size of rod ends, market availability,
cost and force calculation. Front A-arms are designed for quick camber change.
16
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
1.Front A arm –
2- Rear A arm-
17
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
4. Upright:
Uprights are designed considering cost of manufacturing and market availability of other parts.
Aluminum (Al6063T6) is used instead of steel to reduce weight. CNC machining is used for
manufacturing. For finite element analysis, 1.3g cornering and 1.5g braking force is applied according
to the calculation.
1500 N
2750 N
NNNN
NNNN
NNNN
NMM
MMNN
1750N
NN
3000 N
IY9
465
56N
ii. Front upright cornering force
NN
N
18
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
1500 N
1750N
3000 N
2750 N
NNNN
NNNN
NNNN
NMM
5. SPRING MMNN
NN
We are using fluid shocks at the rear and air shocks at the frontIY9
considering the size of damper
465
available in market. Springs are designed and manufactured according to force calculation and size
of dampers. Spring parameters are as follows: 56N
NN
PARAMETERS FRONT N REAR
19
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
4. STEERING SYSTEM
Goals for steering team are to improve steering mechanism compared to last year’s. New
compact and light weight rack and pinion assembly is designed. Reverse Ackermann
geometry is employed.
Fig.1.Steering
Ackerman condition
θi=29.66°, θo=33.164°
1/tanθo-1/tanθi=B/LR=3.6m
These steering ranges were thus made a goal for designing the steering arm and magnitude
of rack travel distance by iteration method on optimum kinematics. After sever alliterations
we get required result as follows:
20
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
Steer angle of outside wheel 33.164°
Turning radius 3525mm
After deciding all the parameter of steering elements then we can calculate the steering effort.
All the force calculation is based on static condition or car just to start the movement of wheel.
Wheel scrub radius 44 mm
Torque to rotate front wheels 50240 N mm
Steering arm length 81 mm
Force on the rack 625 N
Torque on pinion 10045.4 N mm
Steering wheel diameter 125mm
Steering Effort 95 N
As per force calculation, availability and cost. We have selected mild steel for fabrication of
rack and pinion. Knowing the height of the rack, by selecting appropriate rack length to
minimize the bump steer. The circular steering wheel with quick release steering hub is
provided for quick egress in case of emergency.
Pinion
Module 3
Number of teeth 11
Pitch diameter 32 mm
Pressure angle 20°
Face Width 10 mm
Rack
Module 3
Number of teeth 16
Rack height, length 30 m, 440 mm
21
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
3. PICTORIAL REPRESENTATION
4.CONCLUSION
Structural components of vehicle are analyzed for various forces acting on vehicle using basic
principles of mechanics and it is validated by modeling it in finite element software ANSYS.
Fluid flow analysis is done for intake manifold nose of vehicle which shows minimum air
resistance. Structure is safe and the vehicle is equipped with safety equipment. Engine can
deliver optimum speed and power. Team has worked to make vehicle satisfy all the rules and
perform well on race track.
22
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
Sponsorship
• Set Of Wet Tyres Acquired From JK Tyres.
23
Mahatma Gandhi Mission’s College of Engineering and Technology
Kamothe, Navi Mumbai
• The team first participated in SUPRA SAEINDIA 2015 which was then
held at Kari Speedway (Chennai).
• Ever since the team participated in the event, it bought laurels to the
college.
RD
SUPRA 2018 2017-18 80/140 3
24
Smart India Hackathon 2018: A Phenomenal Vision
Smart India Hackathon – 2018 was a software coding competition which involved around 2183
engineering and management colleges and universities from across India. 29 departments of
Government of India participated in this event.
To envisage and promote Hon.Prime Minister Shri. Narendra Modi’s Digital Literacy vision, this
initiative aims to institutionalize a model for harnessing the creativity and technical expertise of
almost 1,00,000 students for direct benefit of our nation.
About 27 Central Government Ministries and 18 State Governments have come together and posted
408 problem statements to the students participating in this grand initiative. More than 105234
students registered. With 17539 ideas are received from technical institutions in India, this surely has
been a fantastic response!
Under the guidance of Prof. P Manivannan, Department of Information Technology, students from
both the disciplines constituted the Team BugSquashers and represented Mahatma Gandhi
mission’s College of Engineering & Technology (MGMCET), Kamothe, Navi Mumbai by
participating the ‘Grand Finale of Smart India Hackathon – 2018 organised by AICTE and
MHRD, which was scheduled on 30th and 31st March 2018 at Banaras Hindu University, Uttar
Pradesh.
The grand event commenced by the arrival of various team from all over India and HigherOfficials
from BHU institute. The problem statement for the team BugSquashers was,“Collection of
information regarding discharge of untreated affluent in river.”
Out of 48 teams participating in the event, “BugSquashers stood 1st runner up by coding
forcontinuous 36 hours and bagging the cash prize of 75,000/- “. It was extremely great moment
for the entire team and college. The young innovative minds could explore the horizons of
technology which is tantamount to the latest technological applications and win Runner- up Trophy.
Team BugSquashers (1ST Runner up) at BHU, Varanasi
The students of Computer Engineering and Information Technology had participated in another event
under the mentorship of Prof. Sachin Chavan, Dept of Computer Engineering and represented
Mahatma Gandhi Mission’s College of Engineering & Technology (MGMCET), Kamothe, Navi
Mumbai. The team ‘Techvist’ got selected for the ‘Grand Finale of Smart India Hackathon –
2018’, which was conducted on 30th and 31st March 2018 at Sri Krishna College of Engineering and
Technology, Coimbatore, Tamil Nadu. The problem statement of our team was ‘Integrated Call
Numbers and Prediction Of Wildfires and Earthquake’. Team Techvist got selected among the
41 teams and received Deloitte Innovation Award and prize amount of 10,000/- INR.
Team TECHVIST(Deloitte Innovation Award)
Under the guidance of Prof. Venkat Raman, students of Information Technology constituted the
team ‘Techminions’ and got selected for the ‘Grand Finale of Smart India Hackathon – 2018’, which
was held on 30st and 31st March 2018 at Panipat Institute of Engineering and Technology.
Out of total 195 ideas received under the Department of Post, Ministry of State(IC) of
Communications, 39 teams were shortlisted for the Grand Finale. The problem statement of our
team was ‘Design and demonstrate a digital addressing system as an extension of the existing
PIN code’. (Problem Code: #DOP6)
The efforts and the approach of the team was appreciated by ministry officials of Department of
Post.
Team TECHMINION
MGM's College of Engineering and Technology
Our Hon’ble Prime Minister Shri. Narendra Modi, envisages a Digital India to bridge
the digital divide in our country and further promote digital literacy in order to
make development a comprehensive mass movement and put governance with
everyone’s reach in India. This initiative aims to institutionalize a model for
harnessing the creativity and technical expertise of 45000 students for direct
benefit of our nation.
Out of total 120 ideas received under the Department of Biotechnology, 30 teams
were shortlisted for the Grand Finale. The problem statement of this team was
‘Online Feedback of Post-graduate students in Biotechnology’.
Team TechNOBI got selected among the top 15 innovative ideas under the
Department of Biotechnology and received prize amount of 10,000/- INR.
Team TechNOBI’s leader Deepak Survase, along with all the team members, are
very thankful to Dr. S. K. Narayankhedkar, Principal of MGMCET, for his continued
support during the preparation of Smart India Hackathon from 20 th Jan, 2017.