SAEINDIA organized

Two day

Faculty Leadership Development

Programme
on 21st & 22nd June 2013

at Priyadarshini College of Engineering,

Nagpur.
Baja Design Report, DFMEA
& Validation Presentation
Dr. K.C. Vora
 BROAD CLASSIFICATION
CHASSIS AND ROLL CAGE SUSPENSION SYSTEM

ENGINE AND TRANSMISSION BRAKES AND STEERING

 Vehicle Configuration
Four or more wheels
wheels..

Capable of carrying single seated person 190. 190.5 cm

(63) tall and weighing 113
113..4 kg (250 pounds).
pounds).

Maximum vehicle width should be less than 64 64

including tyres and maximum length should be less
than 108
108.

It must possess all terrain capability.

capability.

It should have adequate ground clearance and traction.

traction.
 Typical Design Targets
Top speed 50km/hr
Approximate weight 210kg
Ground clearance 9-10
Wheel base 56
Track width 60
Turning radius 8
 Different parts of vehicle
Engine/Air Filter/Silencer
Transmission/Clutch/Differential
Seat
Roll Cage
Body
Axle/Balancing Rods
Suspension
Tyres
Brakes
Steering
Fuel System
Safety
Asthetics/Colour
Spares
Manufacturing Kit/Tool Kit
Innovation
 ENGINE
BAJA SAEINDIA Competitions
require use of Engine provided
by Briggs & Stratton, USA of
following specifications
specifications::

4 stroke air- air-cooled 10 10hp

hp OHV
Intek Model 205432
305cc,
305 cc, 19
19..66
66Nm@
Nm@2800
2800rpm
rpm
79..25
79 25mm
mm bore, 61 61..67
67mm
mm stroke,
8:1 compression ratio
A governor restricts the
maximum speed to 3800 rpm
 POWERTRAIN EXHAUST 8

Engine Crankshaft
Lombardini LGA 340 Briggs & Stratton
Standard Muffler of Sagar
Key Integrated Exhaust
Industries with integrated
Adapter
system
Catalytic Converter
Spacer

Couple
r

Fig. Modified coupler exploded view

PARAMETER VALUE
Max Equivalent
176 MPa
Stress
Max Shear
97.8 MPa
Stress
Max
0.06 mm
Deformation
Fig. F.E. Analysis of adapter Factor of Safety 4.54 Fig. Back pressure of
Exhaust
 Roll Cage
Tubular frame to take the loading and protect the
driver in a rollover.

Roll cage must incorporate appropriate:

Rear roll hoop (RRH)
Lateral diagonal bracing (LDB)
Roll hoop overhead members (RHO)
Lower frame side members (LFS)
Side impact members (SIM)
Front bracing members (FBM)
Fore aft bracing members (FAB)
Lateral cross member (LC)

Helmet, Head Restraint,

Firewall, Fire-
Fire-extinguisher,
Safety Belt, Spares, Design
report, Cost report and
Insurance are mandatory.
 Rear Roll Hoop (RRH)
The rear roll hoop functions
to separate the driver from
the engine.

The fire wall is mounted on

the RRH.

The driver seat may not

protrude the plane of RRH.

The RRH should also be 29

inch or greater at a height of
27 inch from the base of the
drivers seat.
 Rear Roll Hoop Lateral Diagonal
Bracing (LDB)

Lateral bracing for the Rear Roll Hoop will begin at a

point along the vertical portion of the RRH within 12.7
cm (5 in) vertically of point BL or BR and extend
diagonally to a point no farther than 12.7 cm (5 in) above
point AR or AL.
Roll Hoop Overhead Member (RHO)
The RHO shall be
located above the
drivers seat by a
minimum of 104. 104.1
cm (41 inches)
inches)..

Points C should be
located forward of
the drivers seat by a
minimum of 30.30.5 cm
(12 inches)
inches)..
Lower Frame Side Member (LFS)

Lower frame side

members shall
join the RRH and
LC and extend to
points forward of
the drivers heel
to a front lateral
cross member.
member.
 Side Impact Member (SIM)
Side impact members
shall join the RRH at
points S and extend
horizontally to points
SF forward of the
drivers toes.
The SIM should be
between 8 to 12 inc as
measured from the
base of the drivers
seat.
The driver body
should not be in
contact with the SIM
members.
 Front Bracing Member (FBM)

Front bracing
members shall join
the RHO, the SIM
and the LFS
LFS..

The angle between

the FBMUP and the
vertical should be
less than 45
degrees..
degrees
 Rear Bracing Members.

The Rear bracing

acts as a cage
carrying the engine
and transmission
box.

The bracing should

be fully triangulated.
FABRICATION
USE OF DESIGN SOFTWARES

PTC/ANSYS/ALTAIR SOFTWARES
Software design
 Vehicle Dynamics Simulation
Vehicle Data Animation

Math Model
Maneuver

Plots

Road and Wind

Road course,
skidpad, grades,
cross-slopes,
split-mu, crosswind
 Hill Climb Test

At 20kmph

At 30kmph
At 40 kmph
 MATERIAL SELECTION
Steel members with at least
equal bending stiffness and
bending strength. The bending
stiffness and bending strength
have to be calculated about an
axis that gives the lowest value.

Bending stiffness is proportional

by the EI product and bending
strength is given by the value of
SyI/c. M.S. 1.25 O.D. 16gauge
 Material

Material for the frame and chassis

1018 Circular steel tubing with OD 2.5 cm
(1 inch) & wall thickness of 3.05 mm
(0.120 inch).

Equivalent AIS 4130 or BIS 1875.

 Dimensions

Overall Length: 84 inches

Wheel Base: 63.5 inches
Track: Front 50 inches
Rear 52 inches
Overall Weight 300 kg (w/o Driver)
 Rods are cut and welded for
chassis. Pipe bending can be
used as an alternate measure.
 Aim should be to reduce excess weight
without compromising any structural
rigidity or the safety of the driver.

Centre of gravity should be maintained as

low as possible.
The body panels protects the drivers body
and provides a suitable enclosure.
Roll cage padding reduces the damage in
case of impact.
 Specifications

Frame was manufactured to fit a seat that

allowed for maximum driver comfort and safety,
features consumers demand
The swing arm requires the engine to be
mounted rigidly to the frame, and out of the way
from the traveling suspension. This causes the
center of gravity to be moved higher, and
creates much more sprung mass.
Roll cage padding protects drivers head from
impact.
Body
 IMPORTANT SUSPENSION VARIABLES

a0
CAMBER
ANGLE
VARIATION
DIRECTION OF
SUSPENSION
TRAVEL
GROUND
CLEARANCE

TRACK WIDTH
GENERAL OBJECTIVES
The suspension system forms the link between the
frame and the wheels. The suspension of the car
prevents the shocks from the road to reach you.

For All Terrain vehicles the suspension travel should

be as much as possible.
The links and the shockers should be strong enough
to sustain various shocks and fatigue resistant.
The geometry should aid maximum tyre-
tyre-road
contact.
There are many types systems available .
 IMPORTANT DESIGN
CONSIDERATIONS
The ground clearance should be optimum.
The track width may be kept as much as
possible but within the limits specified in the
rules.
Being the main features of all terrain vehicles,
the wheel travel should be as much as possible.
The camber variation should be as less as
possible to improve the tyre
tyre--ground contact
which aids in traction..
 Safety Features
Safety is the primary consideration in the design of Baja
SAE vehicles and the conduct of the competitions.
Teams need to include safety considerations in all parts
of their program.
Roll cage
A head restraint must be provided on the car to limit
rearward motion of the head.
In all cases, a minimum of 15.2 cm (6 inches) vertical
clearance must be provided from the helmet top of the
teams tallest driver to the bottom of the roll cage top
tubes or members.
All drivers must be able to exit on either side of the
vehicle within five (5) seconds.
A firewall between the cockpit and the engine
and fuel tank compartment is mandatory
mandatory.. It must
cover the area between the lower and upper LC
LC..

All drivers must use a minimum of a 4 strap restraint

harness.
What is 4 - Point Harness belt?
Harness Belt means a belt
which is essentially a
combination of lap strap and
diagonal strap across the
shoulder and chest.

It is called as S-
S-type belt
in ECE Regulation.
 WEBBING LOOPS THROUGH THESE SLOTS FOR ADJUSTMENT

Specification STANDARD
FASTENER
STANDARD
FASTENER

1500 MM (ADJUSTER 1500 MM (ADJUSTER

FULLY EXTENDED) STANDARD STANDARD
FULLY EXTENDED)
ADJUSTER ADJUSTER

STANDARD STANDARD STANDARD STANDARD STANDARD STANDARD STANDARD

FASTENER ADJUSTER STITCHING BUCKLE STITCHING ADJUSTER FASTENER

700 MM (ADJUSTER 700 MM (ADJUSTER

170 MM
FULLY EXTENDED) FULLY EXTENDED)

WEBBING LOOPS THROUGH THESE SLOTS FOR ADJUSTMENT

HIGH G CRASH TEST

To Validate belt assembly or a restraint system

affecting the restraint of the occupant shall break and
no buckles or locking system or displacement system
shall release or unlock
 Engineering Design
Engineering design assessment consists
of two events

1) Design Report

2) Design Evaluation
 Design Report
The design report should clearly explain the engineering and design
process that was used in developing each system of the teams Mini
Baja vehicle.

The process for each system could include:

1> Objectives
2> Customer requirements
3> Alternatives considered
4>The result(s) of design calculations
5>Stress Analysis
6>Testing

Design reports must follow the format for SAE Technical Papers
 Design Report - Format
The design report file must be named as follows:

Car #_college name

EXAMPLE: Car # 14 VIT

 Design Report Page Limit
The technical paper segment of design report is limited to
ten (10) pages, excluding the cover page. Additionally the
report may, at the teams option, include up to four (4) non-
text, pages of plans, graphics, photographs or other data for
a maximum of fourteen (14) pages of information. The only
text permitted on the four (4) optional pages are captions.
All pages must be either 8 x 11 or A4.

NOTE: If your paper exceeds 10 pages of technical report or

4 pages of graphics, then only the first 10 technical and 4
graphic pages will be evaluated.
 Design Report Deadline and
Submission
Design reports must be received not later than the due date of
15th Dec 2014.
2014. Any Design Report not received by the due
date will be subject to a penalty of ten (10) points for each day
after the deadline. Both soft & hard copies are required.

Teams that do not submit a Design Report will not be judged

in either part of the Design Event and will receive zero (0)
points.
 Design Evaluation
Design Evaluation will be conducted at the event site on the
first full day of the competition. Cars are expected to be
presented for Design Evaluation in essentially finished
condition, i.e. fully assembled, complete and ready-
ready-to-
to-run.

Vehicles presented in an unfinished condition may receive

lower, or zero points for any incomplete areas that can not
be fully assessed by the design judges. Additionally, the
judges have the right to refuse to evaluate incomplete
vehicles. Teams that are refused judging because of
incompleteness will receive zero points for Design
Evaluation.
 Design Evaluation
During design evaluation team members
are expected to be able to fully explain
and discuss all aspects of their vehicles
design and the rationale behind their
design decisions. Teams that are unable
to adequately explain the various aspects
of their design to the judges satisfaction
will receive lower scores down to, and
including, zero (0) points.
 DFMEA
Design Failure Mode
& Effect Analysis
 Potential
__ System
Failure Mode and Effects Analysis
__ Subsystem (Design FMEA)
__ Component FMEA Number:
Page 1 or 1
Model Year/Vehicle(s): Design Responsibility Prepared by:
FMEA Date (Orig.):
Core Team: Key Date:

Item C Potential O Current Current D Responsibility Action Results

Potential Potential S L C E R. Recommended
Cause(s)/ Design Design & Target
Failure Effect(s) of E A Mechanism(s) C T P. S O D R.
Controls Controls Action(s) Completion Actions
Mode Failure V S U E N.
Date
E C E P.
Function S Of Failure R Prevention Detection C Taken V C T N.

48
 FMEA Procedure
List all Function & Re- evaluate
requirements (New RPN )
List all conceivable Define Responsibility
failure modes & Time- frame
Consider effects, if above
Recommend
failure mode happens
improvements
Look possible causes &
mechanism for Calculate the Risk
failures mode Priority Number (RPN)

Assess the frequency of Assess the possibility of

occurrence of Failure being
failure modes (O) detected ( D )

Assess the Severity of effect (s)

 FMEA Sequence
Subsystem Potential Potential S C Potential O Current Controls D R Recommende Responsi Action results
failure Effect(s) of E L Cause(s) C E P d bility &
mode Failure V A Mechanism(s) C T N Action(s) Target
S of Failure U E completio
S R C n date
T
I
Function O
Requires N

Act- S O D R.
ions E C E P.
take V C T N.
What are the How bad What can be done? n
effect(s)? is it? - Design changes
What are the - Process
Functions, changes
Features or - Special controls
Require- - Changes to
ments? standards,
procedures, or
What can go What are How often guides
wrong? the does it
- No function cause(s)? happen?
- Partial/ over/
degraded
function How can this
- Intermittent be prevented How good is this
function method at
and detected?
- Unintended
detecting it?
function
S.O.D. Tables & its usage
 Occurrence table
Occurrence (o)
Suggested Evaluation Criteria:

Probability of Failure Possible Failure Rates Ranking

Very High : Persistent > 100 per thousand vehicles/ items 10
failures 50per thousand vehicles/ items 9
High : Frequent failures 20 per thousand vehicles/ items 8
10 per thousand vehicles/ items 7
Moderate : Occasional 5 per thousand vehicles/ items 6
failures 2 per thousand vehicles/ items 5
1 per thousand vehicles/ items 4
Low : Relatively few 0.5 per thousand vehicles/ items 3
failures 0.1 per thousand vehicles/ items 2
Remote : Failure is < 0.010 per thousand vehicles/ items 1
unlikely
 Severity table
Effect Criteria : severity of Effect Ranking
Hazardous Very high severity ranking when a potential failure mode affects safe 10
without vehicle operation and/or involves noncompliance with government
warning regulation without warning.
Hazardous Very high severity ranking when a potential failure mode affects 9
with warning safe vehicle operation and/or involves noncompliance with
government regulation with warning.
Very High Vehicle/ item inoperable (loss of primary function). 8
High Vehicle/ item operable but at reduced level of performance. 7
Customer very dissatisfied.
Moderate Vehicle/ item operable, but Comfort/ Convenience item(s) 6
inoperable. Customer dissatisfied.
Low Vehicle/ item operable, but Comfort/ convenience item(s) operable 5
at a reduced level of performance. Customer somewhat dissatisfied.
Very Low Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed 4
by most customers (greater than 75%).
Minor Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed 3
by 50% of customers.
Very Minor Fit & Finish/ Squeak & rattle item does not conform. Defect noticed 2
by discriminating customer (less than 25%).
None No discernible effect. 1
 Detection table
Suggested Evaluation Criteria: For
Detection
Absolute
detection
Criteria : Likelihood of Detection by Design Control
Design control will not and/or can not detect a potential cause/
Ranking
10
Uncertainty mechanism an subsequent failure mode; or there is no Design
control
Very Remote Very remote chance the Design control will detect a potential 9
cause/ mechanism and subsequent failure mode.
Remote Remote chance the Design control will detect a potential cause/ 8
mechanism and subsequent failure mode.
Very Low Very low chance the Design control will detect a potential cause/ 7
mechanism and subsequent failure mode.
Low Low chance the Design control will detect a potential cause/ 6
mechanism and subsequent failure mode.
Moderate Moderate chance the Design control will detect a potential cause/ 5
mechanism and subsequent failure mode.
Moderate High Moderate high chance the Design control will detect a potential 4
cause/ mechanism and subsequent failure mode.
High High chance the Design control will detect a potential cause/ 3
mechanism and subsequent failure mode.
Very High Very high chance the Design control will detect a potential cause/ 2
mechanism and subsequent failure mode.
Almost Certain Design control will almost certainly detect a potential cause/ 1
mechanism an subsequent failure mode.
RPN / Risk Priority Number
Top 20% of Failure
Modes by RPN

R
P
N

Failure Modes
 DVP&R
Design Validation
Plan & Report
 Validation??
Why Design Validation??
Are we building it right?

Major costs of projects are incurred in early design stages.

The cost of fixing a design and faulty decisions at later

stages is exponentially greater than at an earlier stage.

Early involvement of CFT in product development saves

time and money over product life.
 Validation Definition
The documented act of proving that any
procedure, process, equipment, material,
activity or system, actually leads to the
expected results.

Design Validation means establishing by

objective evidence that device specifications
conform to user needs and intended uses.
 Requirements of
Design Validation
Design validation shall be performed under defined
operating conditions on initial production units, lots or
batches, or their equivalents.
It includes testing of production units under actual or
simulated use conditions.
It includes software validation and risk analysis.
The Validation must be documented in Design
Validation Plan.
 Design Validation Process
Validation Plan

Validation Review

Validation Methods

Validation Report
Comparison Between Validation,
Verification & Review
Design Validation Plan (DVP)
Design Validation is next step to DFMEA.

Depending upon RPN in DFMEA the

components are arranged in DVP.

It contains all the information regarding the

acceptance criteria, responsible person or
team, type of test and start & finish dates.
 Validation Methods
Testing ( Static as well as Dynamic)

Analysis ( Using software's and simulations)

Inspection Methods(Visual or with Test Rigs)

Compilation of relevant scientific literature

Study of historical evidences of similar design

Examples of validation methods & activities
Worst case analysis of an assembly.
Fault tree analysis of a process or design.
Failure modes and effects analysis (FMEA).
Package integrity tests.
Testing of materials.
Comparison of a design to previous vehicles
having an established history of successful use.
All the best for BAJA SAEINDIA 2014