FORMULA MON THLY January 2012
Igniting ideas to make a difference A new challenge, a new car and a new team overflowing with innovative ideas, changes are bound to happen. The research phase was completed and the design phase is in process. With the FMXI back from Italy, the disassembling of the car began. The learning process started as the teammates began to correlate things practically. The mighty roar of the powerful Honda CBR 600 RR was indeed an enthralling moment for the team.
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JANUARY UPDATE 2012 ENGINE The Engine team has found out the capacity of the oil pump. CAD models of the exhaust manifold were made and the engine model was modified. The collectors of different half angles were designed using CATIA. The ANSYS simulation of the restrictor was set up and Bell mouth was also made. CATIA render of the 36-1 configuration of the clutch outer, which will be used in this season, thus improving accuracy. (Left) Picture of the point scatter of the oil pan using CoordinateMeasuring Machine (CMM). (Right)
VEHICLE DYNAMICS The preliminary design for the front suspension geometry has been finalized, which has been changed from a push rod mechanism to a pull rod mechanism. In accordance to the ergonomic calculations, the position of the dampers has been changed from top to bottom making the design of the car more compact. The turn radius has been reduced enormously to around 2.8 meters, which is a big achievement for the vehicle dynamics team.
BRAKES On the brakes front, the space for brake and accelerator pedal was reduced in the new design. For reducing the space, the master cylinders were tested in various orientations by preparing the mounting jigs. They will be manufacturing the brake pedal and brake-discs. Also the new wheel assembly was designed on CATIA for testing.
ELECTRONICS The Electronics team is engrossed in Engine-Mapping, Electro-pneumatics shifting, Data acquisition and Display. The new RD Engine Control Unit (E.C.U.) has been purchased. They are also setting up paddle shift along with a fully functional pneumatic system. Elementary programs on LABView for data acquisition were made.
TRANSMISSION The Transmission team has decided to have a foot operated clutch. Electro-Pneumatic circuit was prepared and the system is implemented on static engine with positive results. For better packaging in the rear, the final ratio this year will be 4:1 as compared to 3.69:1 in FM-XI. In order to achieve this 44 and 11 teeth sprocket will be used.
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STRUCTURE The greatest success for this month was the manufacturing of the ergonomic apparatus. The first test chassis design has begun in full swing. One half of the Structure team is engaged in designing the chassis while the other half is planning to devise the jigs for mounting and un-mounting the engine on the chassis.
Wondering what Ergonomics is? Ergonomics is a process which inculcates maximizing user's safety and car's efficiency and reliability. An ergonomic apparatus is designed and manufactured to aid in the design of the car cockpit considering the comfort of the driver while in static condition as well as during the race.
A team member engaged in grinding (left) and welding (right). The team will be manufacturing the new chassis in the near future so they tried their hands on arc-welding, metalcutting, grinding and other mechanical practices.
TEAM MEMBER OF THE MONTH A person who always works with a smile on his face, Rishu is the team member of the month. In his leisure hours he likes to play Counter Strike. Despite the fact that he is from management team, his urge to learn new things has made him try his hands on CATIA and various other manufacturing techniques.
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Wish to be involved with Formula Manipal? With the overwhelming response of the previous year, the team has started the 'BUY a CC' campaign this year as well.This initiative will allow us to integrate our benefactors into the Formula Manipal family.
It was a glorious moment for the team, when the team members proudly displayed their car FM-XI at 'Golden Jubilee International Conference on recent advances and challenges in energy-2012', Which was organized by M.I.T. We are highly indebted to our H.O.D of Mechanical Department, Dr. Divakara Shetty S. and our faculty advisor, Dr. N. Yagnesh Sharma for the giving us the opportunity to be a part of the conference. The conference was attended by notable professors from all over the world. The team gained the praise of all dignitaries present at the conference. They also appreciated the support our various sponsors gave us in making FM-XI a reality. We acknowledge
3DPD, High Calibre, Magod Laser, Race Dynamics and Flame
Pack for having decided to continue supporting us again in the new season. We also welcome our new sponsor for the Season 2013 MRF to the Formula Manipal family.
Design: Siddharth Prakash
OUR 2013 SPONSORS
If you have any ideas/suggestions or queries, please contact: Jimmy Cherian -Team Manager +91 90362-46595
team.manager@formulamanipal.in www.formulamanipal.in
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