15 Day Internship on Supra (F 1) Design and Development

In this part we will be discussing static parts of automobile that how each and every component works:

• Fundamentals of chassis design - Tub chassis (recently used by koenigsegg Agera R), All Terrain Vehicle (ATV) chassis, Sports & passenger car chassis, torsional rigidity of chassis, lite weight materials, welding and joining process
• Suspension system - Double wishbone suspension, Solid Axle suspension, Hotchkiss suspensions, 2 Four-Link suspensions, De Dion suspensions, Air suspension, MacPherson suspension, All Terrain Vehicle (ATV) suspension, suspension isolation
• Braking system - Hydraulic braking, Wedge braking, Power assistance braking, ABS with EBD
• Steering system - Hydraulic power steering, Electric steering, Worm & Sector, Four wheels turning  
• Engine working and fundamentals - Square engines, V cylinder engines, Power-Economy relations
• Types of chassis, Braking, Steering, Suspension and their disadvantages and advantages

In this part we will be discussing dynamics of automobile in deep and discuss how to balance all the components of a car:

• Fundamentals of chassis design - Future vehicles materials technology, Chassis materials, Impact loading, Welding and joining process, Light metals for chassis, Smart materials, simulation of various types of chassis, Tolerance in designing, Bending strength calculation by using software
   
• Aerodynamic forces - Mechanic of air flow around vehicle, Air dams, Bumper spoilers, Deck lid spoiler, Drag coefficient, Rolling resistance, Yawing moment, Pitching moment, Side forces on vehicle, Factors influencing aerodynamic drag
   
• Braking system - Brake design methodology, Kinetic analysis of vehicle, Braking with a constant braking ratio, Brake forces, Aero drag, Rolling resistance, Driveline Drag, Brake performance parameters, Brake stopping distance calculations, Brake stopping time calculation, Combination valves, ABS with EBD, Brake disc heat dissipation theory, Brake Disc Designing, Braking efficiency, Weigh load transfer
   
• Steering system - Steering dynamics, High speed turning, Low speed turning calculations, Four wheel steering mechanism, Turning radius calculations, Critical speed for turning, Over steering, Under steering, Ackerman principle, Rack and Pinion steering, Power steering, EPS, Steering torque, Caster, Camber, Kingpin, Caster trail, Steering kinematics, Steering damper, Tie rod length and position, Characteristics speed, Under-steer gradient, Cornering equations
   
• Engine working and fundamentals - Abnormal combustion in spark ignition engines, Gasoline and Diesel additives, Ignition system overview, Ignition process, Ignition timing selection and control, Mixture preparation, Development of the three-way c catalyst, Durability, Catalyst light-off, Lean-Bum NOx-reducing catalysts, "DENOx, working and explanation of latest technologies like CRDI engine and many more
   
• Transmission fundamentals - Friction clutches torque capability of an axial, Clutch uniform wear, Gear theory, Transmission power flows, Synchronizer operation, Van Doorne continuously variable transmission (CVT), Drive shafts, Hooke's joints shaft whirl, Transmission matching selecting the engine size and final drive ratio for maximum speed, Traction limited acceleration, Traction limits, Transverse weight shift due to drive torque, Dynamic axel loads
   
• Suspension dynamics - Spring and Damper designing, Roll center calculations for different suspension mechanism, Roll Center Analysis, Wishbone suspension Roll Center calculation, Pitch/Bounce frequency, Suspension isolation, Suspension stiffness,  Vehicle motion about the roll axis, Active suspensions, effect on cornering, Roll moment, Camber change, Roll steer

This will be the implementation of the things that we will learn in above two parts:

• Ergonomics considerations in designing of a car
• Ride & handling consideration in design
• Suspension lift point designing
• Chassis designing and stress analysis
• Thermal analysis
• Basic as well as complex surface generation
• Spring modeling
• Steering, Braking & Suspension part modeling and assembly
• Decaling and rendering of a vehicle
• Sub-component assembly
• B.O.M (Bill of material)
• Designing of tire and rim
• Tools & Commands of designing, features – weldments, sketch, evaluate, office products

In this part participants will be fabricate from very scratch which all includes:

• Roll cage profile generation
• Development of roll cage fixtures
• Roll cage welding and weld check confirmation
• Roll cage suspension hard point adjustments
• Development of Double Wish Bone Suspension
• Development of E&T Mounting frame
• Attachment of sub-components holder
• Engine mounting and it’s tuning
• Coupling of engine & transmission
• Brake bleeding and installation of braking, steering assembly
• Final vehicle assembly with all sub-components
  (Steering, Braking, Suspension, E&T, Safety etc.)
• Wheel assembly of front and rear drive vehicles, tire pressure calibration, cornering ability test
• Graphic and Body works

After complete fabrication, participants will do rigorous testing of the FORMULA STUDENT RACE CAR (SUPRA) and will optimize it’s performance

• Acceleration test by participants
• Brake test
• Cornering ability test 
• Vehicle endurance testing 
• Quiz for certificate of appreciation & Internship Opportunities
• Industrial project allotment
• Orientation session on "Career in Automotive Sector"