Spark Racing is the official FSAE Team of Sri Venkateswara College of Engineering, Sriperumbudur. Our Student Formula Car built was driven at FSAE Italy, 2015. Emerged 39th in the combustion category among 55 teams.

1. SUPRA SAEINDIA 2015
VIRTUAL PRESENTATION
SRI VENKATESWARA COLLEGE OF
ENGINEERING
SRIPERUMBUDUR, TAMILNADU
TEAM SPARK RACING

2. TEAM ORGANISATION CHART
TEAM CAPTAIN
ASHWIN KUMAR
VICE CAPTAIN
DHAMODHARAN
TREASURER
SIDDHARTH
ROLLCAGE
DESIGN
DHAMODHARAN
ASWIN
DHANANJAI
SHANMUGHAM BUSINESS
PLANNING&
MARKETING
ISHAAN
CHANDOK
ASHWIN SRI HARI
ARUNESHWAR
STEERING
KAMALAKANAN
GNANAPRAKASH
ABILASH
ELECTRICAL
WIRING&
HARNESS
SIDDHARTH
BALACHANDER
JERRY PRASHANT
BRAKES
VISHAAL
KRISHNA
SUDHAN
PRASHANT
SUSPENSION
SATHISH KUMAR
ASWIN
DHANANJAI
KUNAL.K.DAVEY
YOGEENDRAN
ENGINE&
DRIVETRAIN
GURU
BHARGAV
BALASUNDAR
Department leader
Department leader
Department leaderDepartment leader
Department leader
Department leader
Department leader
FACULTY
ADVISOR
Mr.K.PAUL
DURAI

3. RULEBOOK COMPLIANCE
S.NO RULES DESIGN CRITERIA OUR DESIGN
1 Engine Lesser than or equal to 610 cc 373 cc
2 Wheelbase Greater than or equal to 1525 mm 1549.6 mm
3 Air flow restrictor in intake manifold Diameter of 20 mm 20 mm
4 Vehicle Frame
Vehicle structure must include 2 roll hoops
that are braced, a front bulkhead with
support system, impact attenuator and side
impact structure.
Followed
5 Driver View
Must have a minimum field of vision of 200
degrees by turning head or by the use of
mirrors.
Obtained angle 221°
6 Suspension
When the driver is seated the wheel travel
must be atleast 50.8 mm.
51 mm
7 Wheel diameter Greater than or equal to 8 inches 13 inch
8 Braking system
Single control, 2 independent hydraulic
circuits
Single control, Parallel circuit
hydraulic braking system
9 Ground Clearance
No Part of the bottom side of the vehicle
should touch the ground
Ground Clearance of the vehicle is
51.98 mm
10 Impact Attenuator
Energy absorbing structure capable of
absorbing greater than 7000 J
Carbon fiber – 9310 J

4. OVERALL TECHNICAL SPECIFICATION & PERFORMANCE TARGET
SPECIFICATIONS
OF THE CAR
DETAILS
Engine Used Single cylinder, four stroke,373.2cc
Overall Dimension
Wheel base
2780X1143X1093 mm
1575 mm
Vehicle body
Tubular space frame with light
weight fiberglass panel
Suspension type Double A-arm push rod actuated
Steering system
Self designed rack and pinion type
system
Brakes
Parallel hydraulic actuated floating
disc brakes
Wheels & tyres
13 X6 inches Alloy wheels and
20.5X6 inches tyres
PERFORMANCE TARGETS:
To achieve the following
Real Time accomplishment of calculated design
Weight reduction
High Power/Weight Ratio
High Acceleration
High Stability
High acceleration

5. PROJECT GANTT CHART
COMPLETED
PROJECTED
EVENTS
WE ARE HERE !!!

6. ERGONOMICS
Ergonomic
features
Details
Visibility
Good range of 221° by turning the head
Analogue display gauge above steering wheel
below second roll hoop for better visibility
95th percentile
compliance in
ergonomics
Ergonomic postures
Knee angle - 150°
Foot angle - 95° (When pedal disengaged)
Head room clearance- 55.54 mm
Shoulder harness- 0° to 10° below shoulder
Cockpit
Designed for quick ingress & egress, achieved
through low side member height
Seat thigh support to reduce fatigue while
operating pedals
Safety within
driver’s reach
Kill switches
Fire extinguisher
Detachable
components
Steering wheel (Quick release mechanism)
 Driver seat

7. DESIGN METHODOLOGY FOR ROLL CAGE
MATERIAL CHOSEN FOR
ROLL CAGE
SAE 4130 – ‘CHROMOLY’
METHODOLOGY
Setting dimensions as per
rulebook
Tubular steel space fame
Material selection
Design of rollcage with
proper triangulated joints and
rule book templates
Design to achieve high factor
of safety
Analysis of weak points and
optimization
ANALYSIS TYPE
1D structural and modal
analysis of roll cage
SOFTWARE USED ANSYS 15

8. FINITE ELEMENT ANALYSIS-ROLL CAGE
FRONT IMPACT DEFLECTION REAR IMPACT STRESS
SIDE IMPACT STRESS TORSIONAL STRESS
ANALYSIS LOAD(N)
CONSTRAINTS
Degrees of freedom
arrested
DEFLECTION
(mm)
F.O.
S
Front
Impact
8829
(3g)
FSM-Vertical Translation
RSM-3 Translation
0.469 6.18
Rear
Impact
8829
(3g)
FSM-3 Translation
RSM-Vertical Translation
0.71 4.13
Side
Impact
8829
(3g)
All lower Suspension
Mounting points are
arrested in all 3 translation
6.079 2.16
Roll
Over
8829
(3g)
FSM-Vertical Translation
RSM-3 Translation
1.24 4.21
Torsional
17658
(6g)
RSM-All 3 translation
FSM- Free
19 1.78
• Torsional rigidity – 6455 Nm/deg
• Bending Stiffness- 1536 N/mm
•Modal Analysis of roll cage at 10th mode is 128 Hz.
INFERENCE :`

9. COMPONENTS LOADS
CONSTRAINTS (DOF
ARRESTED)
δ(mm) F.O.S
Front Hub
3g-Vertical &
horizontal
1g Axial(lateral)
Wheel mounting pts – All 3
translation
0.05 3.89
Rear hub
Same Front hub load
&Driving torque
Same as front hub 0.04 5.22
Disc Mounting
Plate
Braking force
Hub mounting pts – All 3
translation
0.02 2.56
Front Upright
3g-vertical &
horizontal
1g-axial(lateral)
Bracket mounting pts – All 3
translation
0.007 4.9
Upper Bracket Same as front upright
A-arm & tie rod mounting
points- All 3 translation
0.032 3.33
Lower
Bracket
Same as front upright Same as upper bracket 0.032 2.42
Rear Upright Same as front upright
A-Arm Mounting Points – All
3Translational DOF.
0.008 1.8
Caliper
bracket
Braking force
Upright mounting pts –all 3
translation
0.058 1.89
COMPONENTS MATERIAL CONSIDERED
WHEEL HUBS Steel (SAE 4340)
WHEEL UPRIGHTS Aluminium(Al 6061 T6)
HUB &UPRIGHTS
Hub
Analysis
Upright
Analysis
Exploded
View

10. SUSPENSION
Suspension type
Double A- arm push rod
activated suspension
Methodology
•Anti dive and Anti squat
were considered in the design
.
•FVSA and SVSA geometry
were used to determine roll
centre, instantaneous centre
and mounting points.
•Good Camber gain was
achieved using linkarm
design diagram
Consideration for selection
Of Materials
•Springs and Dampers
•Based on requirements, costs
and availability
Roll center Front = -30.78 mm
Rear = 37.05 mm
Camber -2°
Caster 8°
Scrub Radius 24 mm
Roll Angle 2.5°
Toe-in 2°
Push rod
suspension
simulation
using
Hyperworks
Line diagram

11. Suspension
Material Used Carbon fiber
F.O.S
Front = 2.5
Rear = 2.98

12. STEERING
CREO MECHANICA- PROPOSED STEERING SYSTEMRACK & PINION EXPLODED VIEW
Steering system type
used
Rack & Pinion
Mechanism
Ackermann mechanism
Degree of rotation
(lock to lock) 210°
Rack Travel
75 mm
Turning Circle Radius
3.8 m
Steering gear ratio 3:1
1.800
2.300
2.800
3.300
3.800
35 36 37 38 39 40
RADIUSOFCURVATURE
(INMETERS)
INSIDE LOCK ANGLE (Ɵ)
INSIDE LOCK ANGLE (Ɵ) VS RADIUS OF
CURVATURE
Rif = (b/sin θ) - ((a-c)/2) Rof= (b/sin φ) + ((a-c)/2)
Rir= (b/tan θ) - ((a-c)/2) Ror= (b/tan φ) + ((a-c)/2)

13. ECU USED
RACE DYNAMICS
POWERTRONICS
FEATURES
Fuel mapping
Ignition mapping
High rev control
PROS
Increases power
Improves combustion
efficiency
Top speed and better
throttle response
KTM 390
RACING
373.2CC
Single cylinder
throttle body injection
of 46mm diameter
Better power to
weight ratio
 Light weight 32 kg
SIX SPEED
GEAR BOX
Performance
32kw(43hp)
TYRE
•HOOSIER – Slick tyre
•Size : 20.5"x 6.0“ inches
• Wider tyres for better
traction
WHEEL
•Chrome plated alloy
wheels, lighter &
stronger
•SIZE - 13"x6“ inches
QUAIFE ATB
FINAL
REDUCTION
 4:1
Chain
Driven Torsen Type
Limited Slip
Differential
POWERTRAIN & DRIVETRAIN
Engine
Mounting

14. TOTAL LENGTH OF
MANIFOLD
250mm(approx.)
CONVERGENCE
ANGLE
14°
DIVERGENCE
ANGLE
6°
CONSTRAINTS
Inlet, Outlet and
Restrictor diameter
TURBULENCE
 Better Fuel-Air
mixing
 Minimal fuel
evaporative loss
INLET CONDITIONS S.T.P
FORMULA USED TO
DETERMINE MASS
FLOW RATE MFR: 0.035 kg/s
INTAKE MANIFOLD
STATIC PRESSURE TURBULENCE ENERGY

15. VEHICLE AERODYNAMICS- SHELL BODY
Air at 27.77 m/s
(100 kmph)
Vehicle shell body
Wind tunnel flow
simulation
Design Methodology Detail optimization
Boundary Conditions
Inlet Conditions S.T.P
Air Velocity 100 Kmph
Turbulent Intensity 10%

16. CONSIDERATION
FOR BRAKE
SELECTION
Hydraulic disc brakes(TVS-Apache)
Size
Cost
Availability
Three mounting points simplifying
Hub design
DESIGN
METHODOLOGY
Parallel Brake Circuit
Petal disc shape for better heat
dissipation
SPECIFICATION
Front Caliper & Rear disc –(TVS )
DISC 200 mm petal disc
Brake fluid  DOT-4
Master cylinder
Caliper
BRAKES
Bore – 25.4 mm
Piston Diameter – 32mm
T-
Joint
Brake
lineBrake
disc
Master
cylinder
Parallel brake circuit

17. BRAKES
Total weight Considered
Total calculated braking
force
Pedal Force
Leverage ratio
Braking Efficiency
360 kg (including driver)
3001.86 N
 355.98N (36.28 kg)
 4.67: 1
 85 %

18. Design Validation
Static:
Testing of reactions forces on each wheel
(Calculation of C.G)
Fluid Leak test
Electric leak testing
Dynamic:
Engine dynamometer
Chassis dynamometer
Chain rig test
Noise level test
IPG carmaker
DESIGN VALIDATION
PROCESS
During this process the
performance of each component is
checked after assembling.
The vehicle performance is
checked using a Chassis
Dynamometer.
Necessary changes are made and
the vehicle is tested On Road.
During Road Test process the
vehicle is run over a series of
tracks with lots of obstacles,
tedious turns, different tractive
surfaces.
Finally the Endurance test is
performed.

19. FACILITIES AVAILABLE AT COLLEGE PREMISES
Name of the Facility Equipments/Mahine/Softwares
CAD / CAM LABORATORY Creo parametric
Ansys 2015
Mathlab works
IPG carmaker
MACHINE SHOP  Hydraulic Pipe Bender
 Centre Lathe
 CNC Lathe – LMW
 Milling Machine
(Universal & Vertical)
 Gear Hobber
 Grinder (Pedestal, Surface
& Cylindrical)
 Shaper and slotter, Planer
 Power Hacksaw machine
 Radial Drilling Machine
 Tool and Cutter Grinder
WELDING RESEARCH
CELL
TIG, MIG, Arc and Gas
Welding
AUTOMOTIVE
COMPONENTS TESTING
LABORATORY
 Chassis Dynamometer
 Engine Dynamometer
 Wheel Alignment
Equipment
 Suspension Test Rig
 Chain Test Rig

20. EQUIPMENT RATING
Driver
Restrain
System
TRS Magnum 6 Point Harness MH460-100—
FIA 8853/98
Helmet OMP GP7K Helmet—Snell SA 2010
Driver Suit OMP Sport Race Suit-FIA 8856-2000
Padding SFI 45.1
Shoes OMP First S Race Boots-- FIA 8856-2000
Arm Restrain SFI 3.3
Fire
Extinguisher
Powder extinguisher homologated by the FIA
Driving
Gloves, Neck
clothing,
Balaclava,
Underclothing
SFI Rated Nomex
DRIVER SAFETY EQUIPMENTS

21. COST REPORT & SPONSORSHIP DETAILS
SPONSORSHIP DETAILS
 SRI VENKATESWARA COLLEGE OF
ENGINEERING
 BAJAJ KTM
 ST ADVANCED COMPOSITES
 CHENNAI SILKS
 MAGNA ENTERPRISES
 SATTVA LOGISTICS PVT LTD
 TAMILNAD TRADERS
 SIMULINK (MATLAB)
 IPG FORMULA CARMAKER
Pie Chart
Code
Department
Total Cost
(in ₹ )
RC Roll cage 90,000
EE Engine & ECU 1,15,000
DT Drivetrain 1,10,000
BS Braking system 45,000
ST Steering System 50,000
SS Suspension System 1,20,000
WT Wheels & tyres 95,000
EW Electrical wiring 30,000
SE Safety equipments 1,00,000
FF Miscellaneous Fits & finish 40,000
Total 7,95,000
Source of Income Amount (in ₹)
Students 5,00,000
College fund 1,50,000
Sponsorship 2,00,000
Total 8,50,000
RC
EE
DT
BS
ST
SS
WT
EW
SE
FF

22. TEAM SPARK RACING THANKS YOU !!!