Formula Monthly - June 2013

Launch Ceremony of The FMX3

Formula Monthly - June 2013

“All our dreams can come true – if we have the courage to pursue them.”

The launch of the fifth creation of Formula Manipal, the FMX3 was held on the 24th of June 2013 at the Innovation Centre in Manipal Institute of Technology.

We were honoured by the presence of our chief guests, Dr. Ramdas M. Pai, Chancellor, Manipal University, Dr. H. S. Ballal, Pro Chancellor, Manipal University and Dr. G. K. Prabhu, Registrar, Manipal University.

The grand launch was also witnessed by university officials, media personnel, college faculty members and our esteemed sponsors.

For more, turn to page 4

2 STRUCTURE The body work of the FMX3 has been received and the team has completed the final assembly of the car. The new impact attenuator of material IMPAXX 700 was assembled on the car. Also the manufacturing of the prototype chassis for the season 2014 car has begun.

VEHICLE DYNAMICS

Monthly Updates

The suspension assembly design of the 2014 car has been completed. Also the steering wheel and steering paddle box were designed and the prototypes were made for ergonomic testing.

Inputs were taken from the drivers and the design has been finalized. The fixtures for steering rack and A-arms were designed and manufactured. Also the team has successfully designed the uprights for the season 2014 car.

ENGINE Flow simulation of the intake manifold for the season 2014 car was done. Preliminary designs for the exhaust primaries and the dry sump oil pan are being prepared. The team is currently working on Ricardo for simulation of exhaust manifold. The engine fixture for the season 2014 car has been finalized and is being manufactured. The team is simultaneously working on composites as it has plans for manufacturing a composite fuel tank.

TRANSMISSION The solid half shafts of the FMX3 were sent to Bangalore for nitriding. The newly manufactured sprockets were received from Gujarat and they have been tested on the running car. Tripod housing profiles of the season 2014 car were 3D printed to check the play of the tripod.

Furthermore, the team has finalized the driveline assembly for the season 2014 car.

ELECTRONICS The electronic mount for the season 2014 car was finalized. The team is now learning programing in C and real time operating system so as to implement electronic systems onto a LPC1769 microcontroller which will allow the team to have more control on the Data Acquisition system, Display system and electro-pneumatic systems. The team is also studying upon engine tuning and engine mapping in order to tune the engine for the 2014 season. Team is also planning to analyse the acquired data and process it into useful information.

Team Member of the Month Rohan Mathur a.k.a. Innu (this child is special) is the Team Member of The Month. He is a second year Automobile Engineering student. An integral part of the Structure team, he has worked tirelessly on the aerodynamics of the car.

Also, his contribution towards the manufacturing of the prototype chassis for the season 2014 car is noteworthy. In his free time he likes to play tennis and chess. Salute to his efforts!!

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Engine mounted on the Engine fixture

A-Arms Fixture

3D Printed Tripod Housing Flow Simulation for the Intake Manifold LPC1769

NEW SPONSORS

COMAU

4 Other officials present at the event included Dr. Vinod V. Thomas, Director, M.I.T, Dr. D. Srikanth Rao, Joint Director, M.I.T, Dr. Manohara Pai, C.E.O, MUTBI, Dr. S. Divakara Shetty, HOD, Dept. of Mechanical and Manufacturing Engineering, M.I.T, and Dr. N. Yagnesh Sharma, Faculty Advisor, Formula Manipal.

Launch Ceremony of The FMX3

Our esteemed sponsors Mr. V. R. Pai from FlamePack Manipal and Mrs. from Jaydev Motors were also present to motivate the team.

The Phoenix Reincarnated under covers before the launch

Chief guest Dr. Ramdas M. Pai and Dr. H. S. Ballal unveiling the FMX3

Team Leader briefs the chief guest about the journey of the FMX3

Team Leader explaining the features of the car to the chief guest The Registrar fascinated by the In-house manufactured Carbon Fibre Steering Wheel

The team flaunting their latest creation

5 Car Number

#96 [ Formula Student Germany 2013 and Formula Student Czech Republic 2013]

Chassis

Front and rear single piece tubular space frame Fusion welding ER70-S6 filler Material – 4130 steel round tubing 0.73o to 1.03o diameter

Body

Glass Fibre Reinforced Plastic

Wheels

13 “ Aluminum Rim-Magnesium center Kiezer wheels

Tyres

Hoosier 20.5 x 6 x 13 R25B

Engine

Honda CBR 600 RR PC-37

Engine Displacement

599 cc

Fuel type

95 RON gasoline

Power

67BHP@8900 RPM

Torque

57N-m@8870 RPM

Brakes

Front and rear disc brake system; PS1 Wilwood Calipers

Suspension

Double wishbone unequal length pull rod actuated Steering Ratio: 3:1 Carbon Fibre Steering Wheel

Steering Transmission

Drexler Differential with 3 pairs of torque biasing ratio Electro-pneumatic gear shifting

Electronics

Race Dynamics RD0901 ECU Wireless data acquisition using cRIO 9004 Real-time RPM Display

Ergonomics

Driver visibility- 210 degree side visibility

Total Weight

254kg

WHAT’S NEXT ???

With the commencement of July a couple of days will remain for testing the FMX3. The team has left no stone unturned for improving the performance of the FMX3. The team will start packing and will ship the car to Austria early next month. The team will be testing the FMX3 in Austria for a week. This will help the team get accustomed to the conditions in Europe before participating in the events, thus giving a competitive edge. The team will then go to Germany for attending Formula Student Germany 2013 which begins on 30th of July 2013. Later on the team will be going to Czech Republic for attending Formula Student Czech Republic 2013 which is to be held on 8th of August 2013.

Meanwhile, the team is also looking forward to complete the manufacturing of the prototype chassis of the season 2014 car and start with the manufacturing of the final chassis and as well as the components for the next season before taking a much deserved break.

Technical Specifications of the FMX3

KNOW THE FMX3

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Interview of the Faculty Advisor

A word with Dr. N. Yagnesh Sharma

Dr. N. Yagnesh Sharma

Sir, please share something about the foundation of the project, Formula Manipal.

The project was a brainchild of Mr. Kaushik Mani. He along with a few other students approached the college for permission to start a project for designing a formula style race car. The college has always been supportive for such student projects and upon seeing the students’ passion towards the project, the college not only granted them the permission but also helped them in the setting up of the required systems and facilities to build a race car.

Sir, please share a little about the progress of the project since its inception.

The project has come a long way since it was founded in 2007. The team has always learned from its preceding teams and it substantially improves its performance at the events. Even this year, the team has improved a lot on the design and performance of the car.

What do you think about the FMX3?

The team has made a more compact, lightweight and an aesthetically appealing car. They have successfully incorporated the electro-pneumatic gear shifting in the car along with a custom made driveline. The car also houses a better data acquisition system and an improved display which allows the driver to assess the engine RPM. The self-designed wheel hubs and the uprights have been crucial in reducing the weight of the car. A better steering geometry has ensured a better driving experience.

What are your views of the 2013 team?

The 2013 team was formed two years ago, after making Formula Manipal a two year project.

The team selection was made more challenging so as to admit only deserving candidates in the team. Ever since, the team has been working enthusiastically and efficiently, as a family, overcoming the challenges put in front of them. They are a coordinated team and have managed their time and resources effectively, making sure not to hamper their academics.

What were your feelings at the launch of the FMX3?

It was a proud moment for me, as the faculty advisor of Formula Manipal, to see the car being unveiled by Dr. Ramdas M. Pai, Chancellor, Manipal University and Dr. H. S. Ballal, ProChancellor, Manipal University. Overall, the ambience of the launch was pleasant. I would like to congratulate the team on the successful launch of the FMX3.

A word to the team members going to the events.

The team has come a long way from the time when the 2013 season started. Finally all your hard work has paid off. With a few days left for the event, keep your morale at its peak. I wish you good luck and may you come out with flying colors at the event.

Any message you would like to convey to the sponsors?

The sponsors have been the backbone of the whole project. Completion of the car would not have been possible without their support. Not only have they helped the team realize their dream of building a car but also helped to hone up their professional skill and put it on a stronger foundation. I am thankful to the sponsors for helping them in their initiative. I look forward to their continued support to our young engineers in the future seasons as well.

Some words of encouragement for the next teams.

You will always have the support of the college but stay in touch with the previous teams, as they will be the best mentors. Take forward the legacy of Formula Manipal of building fine race cars year after year.

About Dr. N. Yagnesh Sharma: Presently the Associate Director (Development), Manipal Institute of Technology, Manipal, Dr. N. Yagnesh Sharma has a Bachelor’s Degree in Mechanical Engineering from University of Mysore and also a Master’s Degree in Thermal Engineering from IIT Madras. After a few years of work experience, he pursued Phd. in Droplet combustion in gas turbines from IIT Kharagpur. Since then, he has been a distinguished and honoured faculty member in the Dept. of Mechanical and Manufacturing Engineering at Manipal Institute of Technology. He also has the distinction of being the faculty advisor for our previous cars, the FM08 and the FMX.

SPECIAL THANKS We would like to extend a thank Shree Ram Trust and Raman Trust for helping us take a step further in our initiative of designing and building India’s finest FSAE car.

LATEST CC BUYERS The following are the CC buyers of the month: 1. R. P. Shruti

4. Sanjeev Sharma

2. Ayush Prakash

5. Udit Prakash

3. Karthik Narayan

6.Vatsal Parikh

A warm welcome to the Formula Manipal Family. We are grateful for your support.

Interview of the Faculty Advisor

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OUR SPONSORS

OUR SPONSORS

JAYDEV MOTORS

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CONTACT DETAILS Rishu Raj Singh Team Manager +91-9008-77-1613 team.manager@formulamanipal.in www.formulamanipal.in

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