TABLE TABLE O F CO NTENTS Introduction.............................................................................................................................................................1 Purpose......................................................................................................................................................................1 Competition
summary.............................................................................................................................................1
Objective....................................................................................................................................................................1 Project
abstract............................................................................................................................................1
Target...........................................................................................................................................................1 Expected features.........................................................................................................................................1 Team
structures........................................................................................................................................................2
Tota l mat eria l specificat specificat ion and cost cost r eport. ............. ................... ............ .............. ............. ............. .............. ........... ............ ............. ............. ............. ............ ............ ............. ..........3 ...3 Time plan(GRANT CHATT) ............................................................................................................................,....5 Assembly-manufacture
layout...............................................................................................................,....6
Production time............................................................................................................................................7 Inn ovat ovat ive or distinct featur es in our vehicle......... vehicle.............. ............ .............. ............. ............. ............. ........... ............ ............. ............. ............. ............. ............. ............. ............. .......8 .8 Frame............................................................................................................................................................8 Parallel and individual pedalling................................................................................................................9 Parallel
derailleur’s.....................................................................................................................................10
Hub gear s with electroma gnetic clutch ar ra ngement ........... ................... ............. ............. ............. ............. ............. ........... ............. ............. ............. .........11 ..11 Kinetic energy storage devices...................................................................................................................12 Front and rear suspension.........................................................................................................................13 Design report............................................................................................................................................................14 Assumptions................................................................................................................................................14 Ma ter ial 6061 alum inium assum pt ion........... ion.................. ............. ............ ............ ............. ............. ............. ............. ............ ............. .............. ............. .............. ..............1 ......14 4 Basic design procedure...............................................................................................................................14 Design calculation.......................................................................................................................................15 Chan drives....................................................................................................................................15 Kinetic energy storage devices......................................................................................................15 Steering calculation.......................................................................................................................16 Axle design.....................................................................................................................................16 Tyre and tube.................................................................................................................................16 Suspension
...............................................................................................................................16
Chassis............................................................................................................................................17 Addit ional ANSYS analysis (not to be calculat ed un der design r eport )............. ).................... ............. .............. ............... .............. .............. ............2 .....25 5
PROPOSED VEHICLE CAD DESIGN
INTRODUCTION THE TEAM HAVE TO DESIGN AND FABRICATE ENERGY EFFICIENT ENTIRLY HUMAN POWERED THREE WHEEL VEHICLES. THE VEHICLE MUST BE AERODYNAMIC, HIGHLY ENGINEERED AND ERGONOMICALLY DESIGNED .THE DESIGN SHOULD BE COMMERCIALLY VIABLE AS APRODUCT AND SHOULD BE ATTRACTIVE TO THE CONSUMERS BECAUSE OF ITS VISUAL APPEARANCE, PERFORMANCE, AND RELIABILITYAND EASE OF OPERATION.
PURPOSE PROVIDE AN OPPORTUNITY FOR ENGINEERING STUDENTS BY SETTING UP A TREND OF USING ECOFRIENDLY VEHICLE IN INDIA AND COME UP WITH SOME INNOVATIVE DESIGNS.STUDENTS HAVE TO TACKLE REAL WORLD ENGINEERING PROBLEMS, WORK IN MULTI DISCIPLINARY TEAMS, PRACTICE AND DESIGN FOR MANUFACTURABILITY AND MANAGE A FULL PRODUCT DEVELOPMENT CYCLE OF LIFE.
COM PETITIO N SUMMARY SUMMARY THE COMPETITION INCLUDES DESIGNING, VALIDATING AND FABRICATING A THHREE WHEELED VEHICLE DRIVEN BY TWO DRIVERS.THE VEHICLE WOULD BE CAPABLE TO BE DRIVEN SIMULTANEOUSLY AS WELL AS ALTERNATIVELY BY TWO DRIVERS.
1. OBJECTIVE •
HUMAN POWER VEHICLE.
• •
TOTALLY ENERGY EFFICIENT. GREEN CYCLE.
•
BEST FIT FOR INDIAN ROADS AND INDIAN PEOPLE.
PRO J EC T ABSTR ABSTR ACT (SUMMARY (SUMMARY))
TARGET •
TOURISTS.
•
LUGGAGE CARRIERS.
•
FOOD STALLS.
•
CAMPAIGNING.
•
SELLS PERSONS
EXPECTED FEATURES • •
• •
• • • •
THREE WHEELED CYCLE USE OF 2 PARRELLEL DERAILLEUR (BOTH OF THE DERAILLEUR CHANGES TO SAME GEAR WHEN APPLIED BY THE FRONT DRIVER) USE OF KINECTIC ENERGY RESTORING SYSTEM (KERS) USE OF 2 PLANETARY GEARS ALONG WITH PROPER CLUTCH ARRANGEMENT IN THE REAR WHEEL FRONT DOUBLE DAMPING SUPER SHOX TELESCOPIC SUSPENSION REAR MONO SUSPENSION ERGONOMICS SEATS AND HANDLE LIGHT WEIGHT 6061 AL ALLOY FRAME WITH SPORTY LOOK
• • • • • • • •
OVAL TUBING FOR UNMATCHED STREGNTH AND RIGIDITY SINGLE –PIECE DESIGN, MAINTANANCE FREE SYSTEM INDIVIDUAL PARALLEL PADELLING FRONT AND REAR DISK BRAKES STABLE LOGGAGE CARRIER DIFFERNTIAL IN THE REAR WHEEL 2 DYNAMOS IN THE REAR WHEEL ONE 12V CELL + ONE 10V CELL FOR ELECTROMAGNETIC CLUTCH
2. TEAM STRUCTURE
SL.NO 1.
NAME S.MURUGAN
DESIGNATION DESIGNATION ASSOCIATE PROFFESOR B-TECH 3RD YEAR STUDENT B-TECH 3RD YEAR STUDENT
BRANCH BRANCH MECHANICAL ENGINEERING MECHANICAL ENGINEERING
RE SPONSIBILITY GUIDANCE OFFICIAL HELP
MECHANICAL ENGINEERING
FRAME ANSYS ANALYSIS,DESIGN OF SUSPENSION
2.
PRADEEPTA KUMAR SAHOO
CAPTAIN-CATIA DESIGN OF FRAME
3.
DIBYENDU MOHANTA
4.
UMAKANTA BEHERA
B-TECH 3RD YEAR STUDENT
MECHANICAL ENGINEERING
ANALYSIS FOR BEST RECUMBENT POSITIONS FOR HPV DRIVE, MESUREMENT,SEARCHING FOR MATERIAL AVAILIBILITY.
5.
SOURAV ANAND SETHI
B-TECH 3RD YEAR STUDENT
ELECTRICAL ENGINEERING
GEAR DESIGN, MEASURE MENT, AND ELECTRICAL ANALYSIS.
3.TOT 3.TOT AL MATERIAL SPECIFI CATION AND AND COST REP ORT SL.N O 1
VEHICLE PARTS
NO.OF REQUIRED PARTS
SPECIFICATIONS /DIMENSIONS
COST
TYRES AND TUBES(FRONT+REAR)
3+3=6
2
RIM(FRONT+REAR)
3
28*1.5
3
HUB WITH BOTTOM BRACKET SHELL (FRONT +REAR) MURD GUARD (FRONT+REAR) FRONT SUSPENSION(FORK)
3
LENGTH- 14CM
RS 35/- PER PIECE TOTAL COST=(3*35)=RS 105/-
3
PLASTIC FIBRE
1
REAR SUSPENSION(SINGLE PIVOTE)
1
DOUBLE SUPER SHOX SUSPENSION LENGTH- 42CM CLOSED COIL HELICAL TORSION BEAM SPRING
RS 60/- PER PIECE TOTAL COST=(3*60)=RS 180/RS 450/-
4 5
6
TYRE RS 140/- PER PIECE +TUBE RS 54/- PER PIECE. TOTAL COST=(3*140)+(3*54)=RS 582/RS 130/- PER PIECE TOTAL COST =(3*130)=RS 390/-
28*1.5
RS 300/-
LENGTH- 18.5CM
7
HANDLE (FRONT+BACK)
2
STRAIGHT
8
HANDLE (FRONT+BACK) BRAKE LEVER
4
RUBBER COATING OVER PLASTIC PLASTIC
9
GREEP
10
DISC BRAKE(REAR+FRONT)
11
FRAME
2 3
12
SEAT
2
13
FRONT AND BACK SPROCKET+CRANK ARM
2+2 PAIRS
DERAILLEURS SET+ SIFT CABLE+SHIFT HOUSING+CHAIN RING+COG SET
2
14
6061 ALLOY ALUMINIUM STEEL OUTER DIAMETER=4.128cm. INNER DIAMETER=3.833cm. WALL=0.147cm. LENGTH=300cm. RUBBER C-50 GRADE STEEL NO.OF TEETH IN SPROKET- 48
THE
C-50 GRADE STEEL NO.OF TEETH FROM THE AXELST 1 GEAR- 28 ND 2 GEAR- 24 3RD GEAR- 21 4TH GEAR- 18 TH 5 GEAR- 15 TH 6 GEAR- 12
RS 50/-(PER PIECE )TOTAL COST=(2*50)=RS 100/RS 4/- PER PIECE TOTAL COST=(4*4)=RS 16/RS 10/- PER PIECE TOTAL COST =(2*10)=RS 20/RS 600/- PER ASSEMBLY TOTAL COST =(3*600)= RS1800/TOTAL COST= (2*1250)= RS 2500/-
RS 80/- PER PIECE TOTAL COST=(2*80)=RS 160/RS 150/-(PER SPROCKET AND PER PAIR OF CRANK ARM) TOTAL COST=(2*150)=RS 300/RS 400/- PER ASSEMBLY TOTAL COST=(2*400)=RS 800/-
15
CHAIN
3
16
PEDAL
2 PAIR
AS PER THE REQUIRED LENGTH FIBER
17
FLIP FL IP FLOP
1
AS PER REQUIREMENT
18
REAR AXEL
1
LENGTH- 1M C-45 GRADE STEEL
RS 180/-
19
PLANETARY HUB(EPICYCLIC)
2
WEIGHT=1Kg SPOKE HOLES=28, 36. AXEL LENGTH=16.3cm. STANDARD OVER LOCK NUT DIMENSION=11cm GEAR RATIO=1:-25% 2:-1:1 3:-33.3%
TOTAL COST=
GEAR
ELECTROMAGNETIC CLUTCH
RS 80 PER PIECE TOTAL COST =(3*80)= RS 240/RS 40/- PER PAIR TOTAL COST=(2*40)=RS 80/RS 60/-
(2*2750)= RS 5500/-
20
CLUTCH ARRANGEMENT
2
21
BATTERY
2
COST=(2*30)= RS 60/-
22
HEAD LIGHT
1
RS 50/-
23
INDICATOR
2
RS 40/-
24
CARRIER
1
25
BACK LIGHT
1
26
FREE WHEEL BUSH+BEARING BUSH
2+1
DIAMETER APPROX
27
KERS
1
WEIGHT=4Kg THICKNESS=34mm. WIDTH=68mm
28
DYNAMO
2
29
PAINT
-
30
TOOLS AND SUPPLIES
-
31
FINISHING MATERIAL
-
32
VEHICLE ENTRY FEE
RS 10000/-
33
TEAM REGISTRATION
RS 2000/-
METALLIC WIRE FRAME STRUCTURE
COST=(2*1000)=RS 2000/-
COST RS 500/RS 45/-
TOTAL EXPENDITURE EXPENDITURE : 18798+10000+20 18798+10000+2000 00 = RS 30798/-
3.81CM
RS 30/- PER PIECE TOTAL COST =(3*30)=RS 90/TOTAL COST=RS 250/-
COST=(2*1000)=RS 2000
4. TIME PLAN-( PLAN-(GRANT GRANT CH ART)
SL .NO
1. 2.
3.
ACTIVITY
-GOT NEWS ABOUT EVENT EFFICYCLE -DOWNLOAD OF RULE BOOK AND OTHER MATERIALS PROVIDED BY EVENT ORGANISERS. -CONSULTING WITH THE SAE COLLEGIATE CLUB FACULTY ADVISOR. -PERMISSION -TEAM SELECTION AND DIVISION -REGISTRATION
RESPONSIBILITY RESPONSIBILITY
ALL TEAM MEMBERS
CAPTAIN KUMAR SAHOO
PRADEEPTA
PRADEEPTA KUMAR SAHOO & SOURAV ANAND SETHI ALL TEAM MEMBERS.
4.
-NET SEARCH ON VARIOUS 3-WHEEL VEHICLES TO GET ROUGH IDEA. -REFERING THEORY AND SEARCH FOR VARIOUS AUTOMOBILE BOOKS.
5.
-VALIDATION OF DESIGN.
6.
-DETAIL HAND DRAWING OF THE DESIGN. -ROUGH CALCULATIONS.
ALL TEAM MEMBERS GIVING THEIR VIEWS.
7.
-FINALISATION OF FRAME DESIGN. -DECISION ON VARIOUS PARTS AND EQUIPMENTS TO BE ATTACHED IN THE CYCLE.
ALL TEAM MEMBERS
8.
LIST OUT OF ALL NECESSARY DEVICES AND HARDWARE MATERIALS TO BE USED ACCORDING TO BICYCLE SCIENCE
ALL TEAM MEMBERS
9.
-COLLECTION OF DETAILS REGARDING THE USE OF FINALISED MATERIALS. -MEASUREMENTS OF VARIOUS CYCLE PARTS ACCORDING TO HUMAN ERGONOMIC POINT OF VIEW CALCULATIONS AND ENQUIRY OF AVAILIBILITY OF ALL THOSE MATERIALS IN LOCAL MARKET. REDESIGNING OF THE NECESSARY CYCLE PARTS FOR BETTER PERFECTION WHEN EVER REQUIRED. DETAIL COMPUTER DESIGN (CATIA ANALYSIS) OF VARIOUS PARTS SEPARATELY. ASSEMBLY OF ALL PARTS TO FORM THE ENTIRE CYCLE. DETAIL ANSYS ANALYSIS OF THE ENTIRE FRAME UNDER VARIOUS LOADED CONDITIONS BOTH STATIC AND DYNAMIC. BRAIN STORMING ON POWER TRAIN.
UMAKANTA BEHERA, SOURAV ANAND SETHI
VALIDATION AND FINALISATION OF DESIGN FOR POWER TRAIN. DESIGN REPORT PREPARATION
ALL TEAM MEMBERS SOURAV ANAND SETHI
COST REPORT PREPARATION
ALL TEAM MEMBERS
COST REDUCTION SUGGESTIONS AND NEGOTIATIONS. FACULTY ADVISOR CONSULTANCY AND DATA COLLECTION REGARDING THE VARIOUS WORKSHOP FACILITIES AVAILABLE FOR THE CYCLE FABRI CATION IF SELECTED. FINAL REPORT SUBMISSION WITH ALL DETAILS, NECESSARY CALCULATIONS AND ANALYSIS.
ALL TEAM MEMBERS
10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
21.
UMAKANTA BEHERA ALL TEAM MEMBERS PRADEEPTA KUMAR SAHOO AND DIBYENDU MOHANTA PRADEEPTA KUMAR SAHOO AND DIBYENDU MOHANTA DIBYENDU MOHANTA
ALL TEAM MEMBERS
ALL TEAM MEMBERS
WEEK 1
WEEK 2
WEEK 3
WEEK 4
WEEK 5
ASSEMBLYASSEMBLY- M ANUFACTURE ANUFACTURE LAYOUTROUND PIPE PROCURED AND AND CUTTING.
PRESSING OF ROUND ROUND PIPESINTO OVAL OVAL PIPE PIPES.
ASSEMBLY OF MAI MAIN N AND AND REAR FRAM AME E WITH WI TH SUSPENSIONS.
WEILDING OF REAR FRAME. FRAM E.
GEAR AND AND SPROCKET ASSEMBLY ON MAIN FRAME.
PEDAL FITTING.
ERGONOMI ONOM ICS CHECKING.
HANDLE AND SEAT ASSEM EMBLY BLY.
FORK WITH WITH
MUD GAURDS, CHAIN FITTING AND COVERING OVERING OF OTHER MACHINE MACHINE PARTS.
CARRIER ASSEM EMBLY BLY ACCORDIN ORDING G TO THE REQU QUIIREMENT.
WHEEL ASSEMBLY.
WHE WHEEL, SEAT, HANDLE, HANDLE, BRAKE, BRAKE CABLE ABLE, GEAR ALLI ALLIGNME GNMENT.
PAINT, OILING, GREESING, AND FINAL TOUCH UP.
FRONT ASSEMBLY SUSPENSION.
ON (MAIN
REAR AXE AXEL FITTING FITTING WITH WI TH KERS, GEARS, HUB GEARS, CLUTCH SYSTEM.
BRAKE FITTING FITTING ALONG WITH WITH FI FITTING OF BRAKE CABLES WITH WI TH BRAKE LEVERS.
CHAIN FITTING.
WEILDING FIXTURES FRAM AME E).
COMPLE OM PLETE PRODUCT.
DRIVE DRIVE TEST, BRAKE TEST, AND AND ELECTRONIC TRONIC TEST.
PRODUCTION PRODUCTION TIM E ACTIVITY ACT IVITY
NO.OF PERSONS FOR A PARTICULAR JOB
TIME PER JOB(SECS)
CUTTING OF TUBES
2
30
PRESSING OF TUBES
1
1
WEILDING
4
30
FRONT FRAME+MAIN FRAME+REAR FRAME+SUSPENSION
2
30
REAR AXEL +SPROCKET+GEAR +SPROCKET+GEAR ASSEMBLY+PEDALS
2
30
WHEELS WHEELS
3
40
CHAIN ARRANGEMENT
3
45
HANDLES AND SEAT
1
40
BRAKE AND GEAR WIRING AND CABLE FITTING
3
45
ERGONOMICS
1
20
CARRIER
2
20
TIM E TAKEN BY 4 PERSONS TO PRODUCE A CYCLE= CYCLE =290 secs= secs=4.833min.(approx.) MAXIMUM PRODUCTION TIME FOR EACH CYCLE =45 secs(app secs(app rox.) SO MORE THAN 2000 CYCLES CAN BE MANUFACTURED IN 20 WORKING HOURS WITH PROPER RELAXTATION RELAXTATION TO THE OPERATORS.
5. INNOVA INNOVATIVE TIVE O R DISTINCT FE ATURES ATURES OF OUR VEHIC LE
1) FRAME-
DESCRIPTIONa) LIGHT WEIGHT b) HIGHLY ERGONOMIC c) LESS NO.OF MEMBERS d) OVAL TUBING FOR UNMATCHED STRENGTH AND RIGI DITY e) SPORTY LOOK f) RIDERS CAN RIDE THE VEHICLE g) ON A 6-10 6-10% % SLOPE QUITE EASILY AND WITHOUT GETTING DOWN FROM THEIR SEATS. SEATS. h) 6061 ALLOY ALUMINIUM TUBES. IMPLIMENTATIONAPPROPRIATE APPROPRIATE VEHICL E FOR CARRYING LOAD WITH LE SS TIME AND CONSUMPT CONSUMPT ION OF LE SS HUMAN HUMAN POWER. ACTS AS A MAIN FRAME CARRING A LOAD OF ABOUT 205Kg (INCLUDING DRIVER PASSENGER AND LOAD). FEASIBILITYa) EASY TO PRODUCE DUE TO LESS NO.OF T UBES, UBES, MEMBERS. b) DESIGN NEED LESS BENDING, TURNIING AND CUTTING. c) CAN BE EASILY EASILY WEIL DED BY “TIG”WEILDING. d) EASY AVAILIBILITY OF 6061 ALUMINIUM ALL OY IN INDIA. e) PRODUCTIONS TIME LESS. COST-
TOT AL COST: RS 2500/ 2500/--
2) PARAL LEL WITH WITH INDIVIDUAL PEDALING-
DESCRIPT ION- TWO CYCLI ST WILL HAVE HAVE INDIVIDUAL INDIVIDUAL PADELING FACILIT Y, MEANS NO ONE ONE IS DEPENDENT ON OTHERS PEDALING SEQUENCE OR TIMING.DIFFERENT CYCLISTS PEDAL IS CONNECTED TO SEPARATE FRONT SPROCKET WHICH ARE CONNECTED TO SEPARATE DERAILLEURES IN THE REAR AXEL THROUGH SEPARATE CHAINS.THIS RESULTS IN ROTATION OF THE REAR AXEL AXEL WIT H THE ADDITION ADDITION EFFORT OF THE TWO C YCLIST THUS REDUCIN REDUCING G THE EFFORT ON THE INDIVIDUAL CYCLIST. GRADUAL INCREASE IN SPEED OF CYCLE BECAUSE OF SYNCHRONISATION OF EFFORT BY BOTH THE DRIVERS. IMPLIMENTATION-TWO DERAILLEURS SETSARE USED FOR PARALLEL PEDALING. A FLIP FLOP HUB IS USED TO DIVIDE THE LENGTH OF THE CHAIN BETWEEN 1 ST FRONT SPROCKET AND THE REAR AXEL IN TO T WO SERIES CHAIN DRIVE DRIVE WHIC H IS INDEPENDENT INDEPENDENT OF ND 2 DRIVER TO PREVENT POWER LOSS DURING TRANSMISSION DUE TO LONGER CHAIN AND TO AVOID VELOCIT Y FLUCTUCTIO N DUE DUE TO SLACKING OF C HAIN.
FEASIBILITYFLIP FLOP C AN BE BE EASILY MADE IN WORKSHOP. DESIRED CHAIN LENGTH IS P OSSIBLE. OSSIBLE. COST- RS 150/150/-(PER (PER SPROCK SPROCK ET AND PER PAIR OF CRANK ARM) TOT AL C OST= (2*150) (2*150) =RS 300/300/-
3) PARALLEL DERAILLLEURSDERAILLLEURS-
DESCRIPTION-TWO REAR AXEL DERAILLEURS WERE CONNECTED IN THE SAME SHAFT.FRONT RIDER DRIVES ONE DERAILLEUR VIA A FLIP FLOP AND THE BACK RIDER DRIVES THE ANOTHER DERAILLEUR. BUT BOTH THE DERAILLEURS WERE CONTROLLED BY THE FRONT RIDER THROUGH A PARALLE CONNECTION OF THE DERAILLEURS CABLE.
IMPLIMENTATION-DUE TO COMMON, PARALLEL CONTROL AND SINGLE CONTROL OF BOTH THE DERAILLEURS THERE IS NO PROBABILITY OF MISMATCH IN POWER TRANSMISSION. FEASIBILITYa) EASY AVA AVAILIBIL ILIBIL ITY OF DERAILLE URS b) CAN BE EASILY FITTE D IN A SINGLE SINGLE SHAFT(REAR AXEL) AXEL) c) BETTE R SPEED AND TORQ UE CONTROL COST - RS 400/400/- PE R ASSEMBLY TOT AL C OST= (2*400) (2*400) =RS 800/800/-
4) HUB GEARS WITH ELECTROMAGNETIC EL ECTROMAGNETIC CLUTCH CL UTCH ARRENGEMENTDESCRIPTION-TWO HUB GEARS (EPICYCLIC GEAR ARRANGEMENTS)WILL BE ATTACHED IN THE RE AE WHEE L HUB WHIC H WILL HEL P IN 3 SPEED GEAR VARIATION.GENERALLY VARIATION.GENERALLY THESE ARE CONTROLLED WITH A CLUTCH ARRANGEMENT AND GEAR ACTUATION IS CONTROLLED BY THE RIDER WITH THE HELP OF A SPEED CONTROLLER.THESE GEAR HUB COMES WITH A GEAR RATIO AS THE FOLLOWING 1ST GEAR - -25% ND 2 GEAR- 1:1 RD 3 GEAR- +33.3% +33.3% OUR AIM IS TO MAKE THE ASSEMBLY TOTALLY AUTOMATIC WHICH WOULD BE GOVERNED BY THE VARIATION OF SPEED.FOR THIS AN ELECTROMAGNETIC CLUTCH IS PROPOSED TO BE USED IN PLACE OF MANUAL MANUAL CLUTCH.. CLUTCH.. IMPLIMENTATIONELECTROMAGNETIC CLUTCH IS COUPLED WITH THE HUB GEAR IN PLACE OF MANUAL CLUTCH.LET THE VOLTAGE REQUIRED FOR THE EM CLUTCH TO GET ACTUATED BE 12V,2 DYNAMO OF 5V RATING ARE CONNECTED IN SERIES WITH THE EM CLUTCH WHICH DERIVES THE POWER FROM BOTH THE REAR WHEELS AND ABETTERY IS CONNECTED TO 2 EM CLUTCH WITH HELP O F A RESISTER WHICH DEVEL OPS A VOLTAGE DROP OF 2V. WHEN DYNAMO DYNAMO ARE WO RKING AT RATED PARAMETER (i.e (i.e VEHICL VEHICL E SPEED 30Km/hr) IT W ILL A GENERATE A VOLTAGE DROP OF 5V EACH, WHICH WILL ADD OF WITH THE 2V EXTRA GIVEN BY BATTERY AND ACTIVATES THE CLUTCH. WHEN THE VEHICLE IS RUNNING AT LESS THAN 30Km/hr VOLTAGE DROP ACROSS EACH DYNA DYNAMO MO IS LE SS THAN 5 V AND AND HENCE THE CLUTCH REMAINS DEACTIVATED DEACTIVATED I N THE HIGHER GEAR RATIO FOR HIGH T ORQUE DRIVE. DRIVE. FEASIBILITYa) IT I S FULLY FEASIBLE, AND AND WILL SURELY HEL P IN AUTOMATIC SIFT ING OF GE ARS AND AND CHANGE IN SPEE D. b) LESS COMPLEXITY IN ELECTRICAL CIRCUIT. COST- TOTAL COST: RS 5500/-
ELECTROMAGNETIC ELECTROMAGNETIC CLUTCH SET-UP
GEAR HUB WITH MANUAL CLUTCH ARRANGEMENT
5) KINECT IC ENERGY RECO VERY SYSTEM SYSTEM (KERS)DESCRIPTI ON- IT IS ALSO CALLED FLYWHEE L ENENRGY STORAGE (FES) WORKS BY ACCELE RATING A FLYWHEEL T O A VERY HIGH SPEED AND MAINTAINING MAINTAINING THE ENERGY IN THE SYSTEM AS ROTATIONAL ENERGY.WHEN ENERGY IA EXTRACTED FR OM THE SYSTEM, SYSTEM, THE F LYWHEEL S ROTATIONAL SPEED IS AS AS A CONSEQUENCE OF PRINCIP LE OF CONSERVATION CONSERVATION OF ENERGY; ADDING ADDING ENERGY TO THE SYSTEM SYSTEM COR RESPONDINGLY RESULTS IN AN INCREASE IN THE SPEED OF THE F LYWHEEL. IMP LIMENT ATION- MAINLY USED USED IN TRAINS TO STORE E NERGY WHILE BREAKING BUT BUT NOW IT I S BEING USED USED IN MANY MANY COMME RCILA VEHICL ES AND AND MAINLY IN F1 TO RECOVER KINECT IC ENERGY AND AND TO MINIMIZE THE ENER GY FLUCTUATION CREATED DURING DURING SYNCHRONISATION SYNCHRONISATION OF BOTH DRIVE CHAIN.THE FOL LOWI NG TABLE TABLE SHOWS THE VARITIO VARITIO N.
FEASIBILITY- EXACT KE RS MAY NOT BE AVAILABLE AVAILABLE AND AND AFFORDABLE AFFORDABLE BUT WE C AN USE USE FES OR W E CAN DESIDN DESIDN AND AND FABRICATE FABRICATE A FL YWHEEL T HAT WILL ACT IN THE SAME WAY AS KERS F UNCTIONS. UNCTIONS. COST- RS 250/-( 250/-(WHEN WHEN FL YWHEEL IS MADE MADE IN W ORKSHOP) TABLE SHOWI HOWING ENERGYFLUCTUATION UCTUATION
SL.NO
STATUS
ST
1
RIDER
2
ND
RIDER
FINAL FINAL SPEED
1. 2.
0 dW
W W
W W
3. 4.
W/2 W
W W
W W
W+dW
W
W+dW
W+dW
W+dW
W+dW
5. 6.
SYNCHRONOUS CONDITION FLUCTUATION PART SYNCHRONOUS CONDITION
7.
CONTINUES TILLFINAL SPEED IS 2W W=ANGULAR VELOCITY OF REAR AXLE dW= INFINITESIMALY SMALL CHANGE IN ANGULAR VELOCITY OF REAR AXLE.
6) FRONT AND REAR SUSPENSION SUSPENSION (FORK)DESCRIPTIONFRONT DOUBLE DAMPING SUPER SUX SUSPENSION REAR SINGLE PIVOTE SUSPENSION a) THESE FORKS HELP HELP IN BETTER HANDLING b) L IGHT WEIGHT FRONT SUSPENSION DUE TO TO AIR INSIDE INSIDE THE THE SYSTEM.
IMPLIMENTATION- IMPLIMENTED TO PROVIDE BETTER COMFORT TO THE RIDERS IN ROUGH ROUDS AND TO ABSORBE BUMPS WHILE BRAKING. FEASIBILITYa) EASY AVAILIBIL ITY OF THE THE FRONT FRONT FORKS. b) THE REAR SUSPENSION SUSPENSION HAS ASIMPLE PIVOTE PIVOTE NEAR THE THE BOTTOM BOTTOM BRACKET AND A SINGLE SWING ARM TO THE REAR AXEL. c) DESIGN SIMPLICITY. SIMPLICITY. d) L ESS NO.OF MOVING PARTS IN THE REAR SINGLE PIVOTE SYSTEM. COST- FRONT SUSPENSION SUSPENSION (FORK)-RS (FORK)-RS 450/-, REAR SINGL SINGL E PIVOTE PIVOTE SUSPENSIONSUSPENSION- RS 300/-TOTAL COST =RS 750/-
FRONT SUPER SHOX SUSPENSION (FORK)
6. DESIGN REPO RT(TEAM -IGNITERKL )
•
ASSUMPTIONASSUMPTION1. MAXIMUM SPEED = 50Km/hr. 2. MAXIMUM WEIGHT OF RIDERS = 2*75=150Kg. 3. MAXIMUM WEIGHT OF THE LOAD = 55Kg. 4. SPRING TRAVEL = 5.08cm. 5. FORCE APPLIED BY EACH RIDER ON PEDAL = 300 N. 6. SERVICE FACTOR FOR CHAIN-LOAD FACTOR=1.25 -LUBRICATION FACTOR=1 -RATING FACTOR=1.2 8. ACCORDING TO HUMAN ERGONOMICS, DISTANCE BETWEEN CENTER OF HANDLE AND SEAT =74cm. 9. MATERIAL BEHAVIOR ASSUMPTIONS APPLIED TO THE ANALYSIS-LINEAR- STRESS IS DIRECTILY PROPORTIONAL TO STRAIN. -CONSTANT-ALL PROPERTIES TEMPERATURE-INDEPENDENT. -HOMOGENEOUS-PROPERTIES DO NOT CHANGE THROUGH OUT THE VOLUME OF THE PART. -ISOTROPIC-MATERIAL PROPERTIES ARE IDENTICAL IN ALL DIRECTIONS.
•
6061 6061 ALUMINIUM ALUMINIUM ALLOY FRI CTI ON WEIL DED MET AL IN FULLY ALLOYED(O) AND AND HEAT TREATED(T6)CONDITION. 1. TENSILE STRENGTH (MPa) - 303-307. 2. YEILD STRENGTH (MPa) – 269-272. 3. HARDNESS (HB) - 96-100. 4. %ELONGATION – 17.8-18.3. 5. MODULUS OF ELASTICITY (GPa) - 68.9. 6. ULTIMATE BEARING STRENGTH (MPa)-607. 7. BEARING YEILD STRENGTH (MPa)-386. 8. POISSON’S RATIO-0.33. 9. FATIGUE STRENGTH (MPa)-96.5. 10. FACTURE TOUGHNESS (MPa-m½)-29. 11. SHEAR MODULUS (GPa)-26. 12. SHEAR STRENGTH (MPa)-207. 13. DENSITY (g/cc)-2.7.
•
BASIC DESIGN PROCEDUREPROCEDURE 1. THE RIDER OF A CYCLE APPLIES FORCE ON THE PEDAL AS A RESULT THE SPROKET ATTACHED TO THE PEDAL CRANK ARM ROTATES. 2. THAT ROTATING SPROKET TRANSMIT ITS ENERGY TO COMPARETIVILY SMALLER GEARS THROUGH CHAINS, WHICH IS FIXED TO THE REAR AXEL CONTAINING THE WHEELS. 3. THUS THE HUMAN POWER IS TRANSMITTED TO THE WHEEL. 4. DERAILLEUR’S ARE USED FOR VARIABLE RATIO TRANSMISSION. 5. FRONT AND REAR SUSPENSIONS ARE DESIGNED AND USED FOR SMOOTH DRIVE AND TO ABSORB BUMPS WHILE BRAKING. 6. KERS (FLYWHEEL)-IT IS ALSO CALLED FLYWHEEL ENENRGY STORAGE (FES) WORKS BY ACCELERATING A FLYWHEEL TO A VERY HIGH SPEED AND MAINTAINING THE
ENERGY IN THE SYSTEM AS ROTATIONAL ENERGY.WHEN ENERGY IS EXTRACTED FROM THE SYSTEM, THE FLYWHEELS ROTATIONAL SPEED IS AS A CONSEQUENCE OF PRINCIPLE OF CONSERVATION OF ENERGY, ADDING ENERGY TO THE SYSTEM CORRESPONDINGLY RESULTS IN AN INCREASE IN THE SPEED OF THE FLYWHEEL. 7. EPICYCLIC GEAR HUBS ARE USE ALONG WITH ELECTROMAGNETIC CLUTC TO INCREASE SPEED. •
DESIGN CALCULATIONSCALCULATIONS CHAIN DRIVE REPORT -FRONT DRIVE SPROCKET: DIAMETER =20.5cm, TEETH=48 TEETH =48 -REAR DERAILLEURS: GEAR NUMBER NUMBER DIAMETER (cm) (cm) 1st 10.5 2nd 9.5 3rd 8.5 4th 7.5 5th 6.5 6th 5.5
NO.OF TEE TH 28 24 21 18 15 12
-PITCH OF THE CHAIN=1.27cm. CHAIN=1.27cm. -VELOCITY RATIO=V.R=N1/N2=T2/T1=2.66 RATIO=V.R =N1/N2=T2/T1=2.66 (ASSUMED AT 4 th GEAR) ALL CALCULATIONS DONE DONE ON 4 th GEAR AS MEAN GEAR. -LOAD=850Kg. LOAD=850Kg. -SERVICE FACTOR=Ks=1.562. FACTOR=Ks=1.562. -AVERAGE VELOCITY OF CHAIN= CHAIN= (p*T*N)/60= (0.0127*48*1240.6)/60=12.6m/sec. -PER MISSIBLE SPEED OF SMALLER SPROC KET ASSUMED=N1 ASSUMED=N1= = 3300rpm. -SPEED OF LARGER SPROCKET=N2=1240.6rpm. SPROCKET=N2=1240.6rpm. -BREAKING STRENGTH =Wb =106*12.7*(PER mm WIDTH OF CHAIN) =106*12.7*7.75=10433.05N. -FACTOR OF SAFETY=Wb/W=10433.05/850=12.27. SAFETY=Wb/W =10433.05/850=12.27. -POWER TRANSMITTE TRANSMITTE D=P= =P= (Wb*V)/ (n*Ks) = (10433.05*12.6)/ (12.27*1.562) =6KW (APPROX). CHAIN SPECI FICATIO N
1st PERSON(DRIVER)
2nd PERSON(PASSENGER)
CENTER DISTANCE NO.OF LINKS=K=(T1+T2)/(2)+(2*x)/(p)+(T2T1) 2 /(2*3.14)*(p)/x LENGTH OF CHAIN(Kp) WEIGHT OF CHAIN
87.5cm 172
33.5cm 87
217.33cm 1.3671Kg
110.5cm 0.69Kg
FLYWHEEL ENERGY STORAGE STORAGE POWER TRANSMITTED =6KW. (FROM CHAIN DRIVE REPORT) REAR SPROCKET=3300 rpm. ENERGY REVOLUTION PER REVOLUTION=E= (P*60)/N= (6*1000*60)/3300=109.09N-m. COEFFICIENT OF FLUCTUATION OF SPEED=Cs=0.04(assumed) ENERGY FLUCTUTION: 30% OF ENERGY = E=0.3*109.09=32.727N-m. E=0.3*109.09=32.72 7N-m. 1. MASS OF THE FLYWHEEL= VELOCITY OF FLYWHEEL=V=14m/sec (ASSUMED.) DIAMETER OF THE FLYWHEEL=D= (V*60)/ ( ) = (14*60)/ (3.14*3300) =0.08m. WE KNOW THAT THE MAXIMUM FLUCTUATION OF ENERGY= E=32.727N-m. E=M*V2*Cs, M=4.175Kg. M=4.175Kg .
2. CROSS – SECTIONAL DIMENSION OF THE FLYWHEEL RIM. = t=THICKNESS OF THE RIM IN METERS. b=WIDTH OF THE FLYWHEEL RIM IN METERS=2*t. CROSS SECTIONAL AREA OF THE FLYWHEEL RIM=A=b*t=2*t 2. NOW MASS =M=A* DENSITY=2*t 2*3.14*0.08*7200 t=0.0339m=3.4c t=0.0339m=3.4cm m (app r ox.) ox.) STEERING CALCULATIONS SPECI FIC ATIONS USED USED BY US: FORK LENGTH – 45cm OFFSET– OFFSET – 4cm HEAD ANGLE ANGLE – 70 degree MECHANICAL MECHANICAL TRAILTRAIL - 6.45cm (CALCULATED BELOW) WHEEL FLOP FACTOR=2.073(CALCULATED FACTOR =2.073(CALCULATED BELOW) RADIUS OF THE WHEELWHEEL - 32cm (INCLUDING TYRE) RAKE ANGLE USED IN BICYCLE=15-20 BICYCLE= 15-20 degree. TRAIL CALCULATION: CALCULATION:
USING THE EQUQTION: TRAIL = (32*cos (70) – 4)/ sin (70) = 6.45 cm WHERE, Rw WHEEL RADIUS Ah IS THE HEAD ANGLE MEASURED CLOCK WISE FROM THE HORIZONTAL O f IS THE OFFSET OR RAKE. WHEEL FLOP CALCULATION: CALCULATION: USING THE EQUATION: f = b sin ∂ cos ∂ = (b sin2∂)/2 f = (6.45*sin140)/2 = 2.073cm. WHERE: f = "WHEEL FLOP FACTOR," THE DISTANCE THAT THE CENTREOF THE FRONT WHEEL AXLE WHEN THE HANDLE BARS AREROTATED FROM THE STRAIGHTAHEAD POSITION TO APOSITION 90 DEGREE AWAY FROM THE STRAIGHT HEAD. b = TRAIL ∂ = HEAD ANGLE
AXLE MAXIMUM FORCE BY DRIVER=F=300N DRIVER =F=300N (GRAPH SEE BELOW). FRONT SPROCKET DIAMETER= DIAMETER = 20.5cm, NO.OF NO.OF T EETH= EETH = 48. AVERAGE AXLE DIAMETER OF REAR SPROCKET =7.5cm, NO.OF NO.OF TE ETH=18. ETH =18. CRANK CRANK LE NGTH NGTH=20cm =20cm (DESIGNED). RADIUS RADIUS OF WHEE L = 32cm. MAXIMUM VELOCITY OF VEHICLE , V=50Km/hr.(assumed.) Wrear =V/r=43.375 rad/sec. Wfront= Wfront = (Nrear/Nfront)*W rear= (18/48)*43.375=16.26 rad/sec. Pfront=Tfront*Wfront=975.6W. Pfront =Tfront*Wfront=975.6W. TENSION IN THE CHAIN (P)=Tfront/r=60/0.205=292.68. (P)=Tfront/r=60/0.205=292.68. Trear=292.688*0.075=21.95N-m. Trear =292.688*0.075=21.95N-m. SO, DIAMETER OF REAR AXLE REQUIRED, D = (16/ (3.14* τ allowed) allowed)*(M *(M2 +T2)1/2)1/3. T=Trear =21.95N-m M =391.29N- M (FROM BENDING MOMENT DIAGRAM) SAFETY FACTOR=10.08=10(CALCULATED) FACTOR =10.08=10(CALCULATED) THEREFORE D=35.48mm =1.39”.
USING FACTOR OF SAFETY=15(BY ANSYS) THEREFORE D=40.62mm=1.59” SO, DIAMETER OF REAR AXLE=1.5” TYRE AND TUBE DIAMETER - 28” WIDTH - 1.5” WHEEL STATIC CAMBER – 2 DEGREE (NEGATIVE) ON BOTH THE REAR WHEELS SUSPENSION SPRING TRAVEL = 5.08cm. SPRING RATE = 64.8 N/mm. (calculated)
GRAPH USED TO DETREMINE MAXIMUM FORCE APPLIED BY HUMAN ON PEDAL
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CHASSIS: STRUCTURAL PARTS ANALYSIS USING ANSYS 12.0 LOAD SET UP
The above loads were applied on the chassis at required points in order to analyze the load bearing capabilities of the frame.
Von-Mises Stress
Information Extracted : Max Stress – 44.008 MPa. The chassis was found to be stable under static loading condition.
Maximum Principal Stress
REAR AXLE ANALYSIS
Von-Mises Stress
SAFETY FACTOR
A safety factor (F.S) – 15 is found out and is utilized while designing the rear axle.
Maximum Principal Stress
CHANGES IMPLE MENTED IN DESIGN AFTER ANA ANALYSIS LYSIS
The previously designed chassis had a stress concentration zone i.e it had greater chances of failure after analyzed in Ansys, as shown in the first diagram below. To overcome the same, we made modifications to it by introducing stiffners at the places previously affected by it and it was found out that the problem was resolved b y doing so
Stress Concentration
AFTER USING STIFFNERS
Stiffners
Comments
PRADEEPTA KUMAR SAHOO (CAPTAIN)
ADDITIONAL ANSYS ANALYSIS (NOT (NOT TO BE CALCULATED CALCULATE D UND UNDER ER M AIN DESIG DESIGN N REPORT)
Project First Saved Wednesday, June 30, 30, 2010 Last Saved Wednesday, June 30, 2010 Product Version 12.0.1 Release
Contents •
Units
•
Model (A4) Geometry o Parts Coordinate Systems o Connections o Contact Regions Fixed - Part 1 To Part 4 Mesh o Static Str Str uctura l (A5) (A5) o Analysis Settings Loads Solution (A6) Solution Information Results Stress Tool Safety Factor §
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§ § §
§ § §
§
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Material Data Structural Steel o Aluminum Alloy o
Units Unit System Angle Rotational Velocity Temperature
TABLE 1 Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius Degrees rad/s Celsius
Model (A4) Geometry TABLE 2 Mod el (A4) > Geom Geom etry Object Name Geometry State Fully Defined Definition Source C:\Users\pop5du\Desktop\chassis_assembled_final.igs Type Iges Length Unit Meters Element Control Program Controlled Display Style Part Color Bounding Box Length X 724.04 mm Length Y 1346.6 mm Length Z 555.77 mm Properties Volume 5.077e+006 mm³ Mass 21.895 kg Scale Factor Value 1. Statistics Bodies 7 Active Bodies 7
Nodes Elements Mesh Metric
26894 13228 None Preferences
Import Solid Bodies Parameter Processing Personal Parameter Key CAD Associativity Import Using Instances Attach File Via Temp File Temporary Directory Analysis Type Enclosure and Symmetry Processing
Object Name State
TABLE 3 Model (A4) > Geometry > Parts Part 2 Part 3 rear_axle_holder Meshed Graphics Properties Yes 1 Definition No Flexible Default Coordinate System
spring
Visible Transparency Suppressed Stiffness Behavior Coordinate System Reference Temperature
Volume Mass Centroid X Centroid Y Centroid Z
Part 5
By Environment
Assignment Structural Steel Nonlinear Effects Thermal Strain Effects Length X Length Y Length Z
Yes Yes DS Yes Yes Yes C:\Users\pop5du\AppData\Local C:\Users\pop5du\ AppData\Local\Temp \Temp 3-D Yes
67.293 mm 125.34 mm 213.8 mm 1.533e+005 mm³ 1.2034 kg 4.4174e-002 mm 1168.4 mm -62.461 mm
Material Aluminum Alloy
Structural Steel
Aluminum Alloy
724.04 mm 249.2 mm 285. mm
38. mm 448.09 mm 242.64 mm
Yes Yes Bounding Box 277.46 mm 104.22 mm 213.63 mm Properties 2.8653e+005 2.8652e+005 mm³ mm³ 0.7937 kg 0.79366 kg
10.899 kg
5.3937e+005 mm³ 1.4941 kg
-194.37 mm
-1.4507 mm
4.3733e-005 mm
1233.6 mm -279.3 mm -279.29 mm
1225.6 mm -272.85 mm 1.0312e+005 kg·mm² 5.6418e+005 kg·mm² 4.7044e+005 kg·mm²
249.79 mm -55.764 mm
192.98 mm
Moment of Inertia Ip1 3816.8 kg·mm² kg·m m²
118.45 kg·mm²
118.47 kg·mm² kg· mm²
Moment of Inertia Ip2 3822.1 kg·mm² kg·m m²
6765.1 kg·mm²
6764.9 kg·mm² kg· mm²
Moment of Inertia Ip3
502. kg·mm² kg·m m²
6766.9 kg·mm²
6766.7 kg·mm² kg· mm²
4643 2195
379 152
1.3884e+006 mm³
28121 kg·mm² 267.18 kg·mm² 28123 kg·mm²
Statistics Nodes Elements Mesh Metric
415 178 None
TABLE 4 Model (A4) > Geometry > Parts Object Name Part 6 chassis State Meshed Graphics Properties
4213 2058
633 110
Visible Transparency
Yes 1 Definition
Suppressed Stiffness Behavior Coordinate System Reference Temperature Assignment Nonlinear Effects Thermal Strain Effects Length X Length Y Length Z Volume Mass Centroid X Centroid Y Centroid Z Moment of Inertia Ip1 Moment of Inertia Ip2 Moment of Inertia Ip3 Nodes Elements
No Flexible Default Coordinate System By Environment Material Aluminum Alloy Yes Yes Bounding Box 38. mm 80. mm 447.67 mm 1196.7 mm 249.25 mm 545.77 mm Properties 5.3554e+005 mm³ 1.8873e+006 mm³ 1.4834 kg 5.2277 kg -7.1344e-004 mm -2.0958e-003 mm 708.6 mm 581.86 mm -280.26 mm -138.82 mm 27787 kg·mm² 7.0403e+005 kg·mm² 263.51 kg·mm² 85608 kg·mm² 27792 kg·mm² 6.2003e+005 kg·mm² Statistics 633 15978 280 8255
Coordinate Systems TABLE 5 Model (A4) > Coordinate Systems > Coordinate System Object Name Global Coordinate System State Fully Defined Definition Type Cartesian Ansys System Number 0. Origin Origin X 0. mm Origin Y 0. mm Origin Z 0. mm Directional Vectors X Axis Data [ 1. 0. 0. ] Y Axis Data [ 0. 1. 0. ] Z Axis Data [ 0. 0. 1. ]
Connections TABLE 6 Model (A4) (A4) > Connection s Object Name Connections State Fully Defined Auto Detection
Generate Contact On Update Yes Tolerance Type Slider Tolerance Value 4.0669 mm Face/Face Yes Priority Include All Group By Bodies Revolute Joints Yes Fixed Joints Yes TABLE 7 Model (A4) > Connection s > Contact Regions Object Name Bonded - Part 1 To Part 7 Bonded - Part 4 To Part 7 State Fully Defined Scope Scoping Method Geometry Selecti on Contact 1 Face 2 Faces Target 2 Faces Contact Bodies spring rear_axle_holder rear_axle_holde r Target Bodies chassis Definition Type Bonded Scope Mode Manual Behavior Symmetric Suppressed No TABLE 8 Model (A4) (A4) > Connectio Connectio ns > Join ts Object Name Fixed - Part 1 To Part 4 State Fully Defined Definition Connection Type Body-Body Type Fixed Suppressed No Reference Scoping Method Geometry Selection Selectio n Scope 2 Faces Body spring Coordinate System Reference Coordinate System Behavior Rigid Pinball Region All Mobile Scoping Method Geometry Selection Selectio n Scope 2 Faces Body rear_axle_holder Initial Position Unchanged Behavior Rigid Pinball Region All
Mesh TABLE 9 Model (A4) > Mesh Mesh Object Name Mesh State Solved Defaults Physics Preference Mechanical Mechanic al
Relevance 0 Sizing Use Advanced Size Function Functio n Off Relevance Center Coarse Element Size Default Initial Size Seed Active Assembly Smoothing Medium Transition Fast Span Angle Center Coarse Minimum Edge Length 3.0654e-003 mm Inflation Use Automatic Tet Inflation Inflatio n None Inflation Option Option Smooth Transiti Transition on Transition Ratio 0.272 Maximum Layers 5 Growth Rate 1.2 Inflation Algorithm Pre Statistics Nodes 26894 Elements 13228 Mesh Metric None
Static Sta tic Struct ural (A5) (A5) TABLE 10 Model (A4) > Analysis Object Name Static Structural (A5) State Solved Definition Physics Type Structural Analysis Type Static Structural Solver Target ANSYS Mechanical Options Environment Temperature 22. °C Generate Input Only No TABLE 11 Model (A4) > Static Structur al (A5) (A5) > Analysis Settin gs Object Name Analysis Settings State Fully Defined Step Controls Number Of Steps 1. Current Step Number 1. Step End Time 1. s Auto Time Time Stepping Program Controlled Solver Controls Solver Type Type Program Controlled Weak Springs Springs Program Controlled Nonlinear Controls Force Convergence Convergence Program Controlled Moment Convergence Convergence Program Controlled Displacement Convergence Program P rogram Controlled Rotation Convergence Convergence Program Controlled Line Search Program Pro gram Controlled Output Controls Calculate Stress Yes Calculate Strain Yes
Calculate Results At
All Time Points
TABLE 12 Model (A4) > Static Structural (A5) > Loads Object Name Fixed Support Force Force 2 Force 3 State Fully Defined Scope Scoping Method Geometry Selecti on Geometry 17 Faces 1 Face 2 Faces Definition Type Fixed Support Force Suppressed No Define By Vector Magnitude 750. N (ramped) 550. N (ramped) Direction Defined FIGURE 1 Model (A4) > Static Structural (A5) > Force
FIGURE 2 Model (A4) > Static Structural (A5) > Force 2
FIGURE 3 Model (A4) > Static Structural (A5) > Force 3
Solution (A6 (A6)) TABLE 13 Model (A4) > Static Static Stru ctural (A5) (A5) > Solution Object Name Solution (A6) State Solved Adaptive Mesh Refinement Max Refinement Loops 1. Refinement Depth 2. TABLE 14 Model (A4) > Static Structur al (A5) (A5) > Solution (A6) (A6) > Solution Info rmation Object Name Solution Information State Solved Solution Information Solution Output Solver Output Newton-Raphson Residuals 0 Update Interval 2.5 s Display Points All
Object Name State Scoping Method Geometry Type Minimum Maximum Minimum Occurs On Maximum Occurs On
TABLE 15 Model (A4) > Static Static Stru ctural (A5) > Solution (A6) (A6) > Result Result s Total Maximum Principal Minimum Principal Equivalent Stress Deformation Stress Stress Solved Scope Geometry Selection Selecti on All Bodies Definition Total Equivalent (vonMaximum Principal Minimum Principal Deformation Mises) Stress Stress Stress Results 0. mm 0. MPa -8.7599 MPa -46.471 MPa 0.99403 mm 44.008 MPa 45.883 MPa 8.315 MPa Part 2 chassis
chassis
rear_axle_holder rear_axle_holder
rear_axle_holder
TABLE 16 Model (A4) > Static Structural (A5) > Solution (A6) > Stress Safety Tools
Maximum Shear Stress
Maximum Shear Stress 0. MPa 23.986 MPa Part 2
Object Name Stress Tool State Solved Definition Theory Max Equivalent Stress Stress Limit Type Type Tensile Yield Per Material TABLE 17 Model (A4) > Static Structural (A5) > Solution (A6) > Stress Tool > Results Object Name Safety Factor State Solved Scope Scoping Method Geometry Selection Geometry All Bodies Definition Type Safety Factor By Time Display Time Last Calculate Calculat e Time History Yes Use Average Yes Identifier Results Minimum 7.2446 Minimum Occurs On chassis
Mater Ma terial ial Data Structural Steel TABLE 18 Structu ral Steel Steel > Const Const ants Density 7.85e-006 kg mm^-3 Coefficient of Thermal Expansion 1.2e-005 C^-1 Specific Heat 4.34e+005 mJ kg^-1 C^-1 Thermal Conductivity 6.05e-002 W mm^-1 mm^-1 C^-1 Resistivity 1.7e-004 ohm mm TABLE 19 Structu ral Steel Steel > Compressive Ultim ate Strength Strength Compressive Ultimate Strength MPa 0 TABLE 20 Structu ral Steel Steel > Compressive Yield Streng th Compressive Yield Strength MPa 377 TABLE 21 Structu ral Steel Steel > Tensi Tensi le Yield Strength Tensile Yield Strength MPa 377 TABLE 22 Structu ral Steel Steel > Tensi Tensi le Ultimate Strength Tensile Ultimate Strength MPa 583 TABLE 23 Structu ral Steel Steel > Alternating Stress
Alternating Alternatin g Stress MPa 3999 2827 1896 1413 1069 441 262 214 138 114 86.2
Strength Coefficient MPa 920
Cycles Mean Stress MPa 10 0 20 0 50 0 100 0 200 0 2000 0 10000 0 20000 0 1.e+005 0 2.e+005 0 1.e+006 0
TABLE 24 Structu ral Steel > Strain-Life Paramete Parameters rs Strength Ductility Ductility Cyclic Strength Cyclic Strain Hardening Exponent Coefficient Exponent Coefficient MPa Exponent -0.106 0.213 -0.47 1000 0.2 TABLE 25 Structu ral Steel > Relative Relative Permeabili Permeabili ty Relative Permeability 10000 TABLE 26 Structu ral Steel Steel > Isotro Isotro pic Elasticit y Temperature C Young' s Modulus MPa MPa Poisson's Ratio 2.e+005 0.3
Aluminum Alloy TABLE 27 Aluminum Allo y > Constants Constants Density 2.77e-006 kg mm^-3 Coefficient of Thermal Expansion 2.3e-005 C^-1 Specific Heat 8.75e+005 mJ kg^-1 C^-1 TABLE 28 Aluminum Alloy > Compressive Ultimate Strength Compressive Ultimate Strength MPa 0 TABLE 29 Aluminum Alloy > Compressive Yield Strength Compressive Yield Strength MPa 280 TABLE 30 Alumi num Allo y > Tensil Tensil e Yield Yield Strength Tensile Yield Strength MPa 280 TABLE 31 Alumi num All oy > Tensil Tensil e Ultimate Strength Strength Tensile Ultimate Strength MPa 310 TABLE 32 Aluminum Al loy > Thermal Thermal Conductivity
Thermal Conductivity W mm^-1 mm^-1 C^-1 Temperature C 0.114 -100 0.144 0 0.165 100 0.175 200 TABLE 33 Aluminum Alloy > Alternating Stress Alternating Alternatin g Stress MPa Cycles R-Ratio 275.8 1700 -1 241.3 5000 -1 206.8 34000 -1 172.4 1.4e+005 -1 137.9 8.e+005 -1 117.2 2.4e+006 -1 89.63 5.5e+007 -1 82.74 1.e+008 -1 170.6 50000 -0.5 139.6 3.5e+005 -0.5 108.6 3.7e+006 -0.5 87.91 1.4e+007 -0.5 77.57 5.e+007 -0.5 72.39 1.e+008 -0.5 144.8 50000 0 120.7 1.9e+005 0 103.4 1.3e+006 0 93.08 4.4e+006 0 86.18 1.2e+007 0 72.39 1.e+008 0 74.12 3.e+005 0.5 70.67 1.5e+006 0.5 66.36 1.2e+007 0.5 62.05 1.e+008 0.5 TABLE 34 Aluminum Alloy > Relative Permeability Relative Permeability 1 TABLE 35 Aluminum Alloy > Resistivity Resistivity Resistivity ohm mm Temperature Tempera ture C 2.43e-005 0 2.67e-005 20 3.63e-005 100 TABLE 36 Aluminum Alloy > Isotropic Elasticity Elasticity Temperature C Young' s Modulus MPa MPa Poisson's Ratio 71000 0.33
