Internship Report Volkswagen India Pvt Ltd.

Name:- Pulkit Sharma

Department:- Motorsports

Internship period:- 12/5/2015 – 12/6/2015( 1 month)

College:- Birla Institute of Technology, Mesra, Ranchi

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ACKNOWLEDGEMENT

I thank Mr Sirish Vissa (HOD, Volkswagen Motorsports India) for making me a part of their

valuable internship program of 1 month & giving me an opportunity to learn and experience

the real world of motorsports.

I express my sincere gratitude towards my mentor Mr. Prasad (Technical Head, Volkswagen

Motorsports) and Mr. Mahesh Menon (Assistant Manager - Technical) for guiding and

supporting me at every step. Without their constant supervision, this project wouldn’t have

taken its present shape. I sincerely thank them for all their time and invaluable inputs.

I also thank Mr. Prajish Nambiar (HR - Department) and Mr. Bharat Gaikwad for giving me

this golden opportunity of interning in Volkswagen India Pvt. Ltd, Pune.

Pulkit Sharma

Internship candidate

Volkswagen Motorsports India

Volkswagen India Pvt. Ltd.

|E-1, MIDC Industrial Area (Phase III)|

|Village Nigoje Mhalunge | Kharabwadi I Chakan I

|Pune I Maharashtra I 410 501 I INDIA |

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Index

1. Introduction to company:- 3

1.1 Volkswagen the group

1.2 Volkswagen India Pvt. Ltd. - Chakan Plant Overview

2. Volkswagen Motorsports India:- 5

2.1 History- Making a debut in the Indian motorsport scenario

2.2 Season 2013- The Year of proving their mettle

2.3 Season 2014- The year of surprises

2.4 Volkswagen Vento Cup 2015 - A new era

3. Projects:- 10

3.1 Side jack for a rally car

4. Components designed:- 15

4.1 Underbody bracket

4.2 Bumper bracket

4.3 Damper spacer

4.4 Exhaust manifold flange

4.5 Catalytic converter flange

4.6 Exhaust flange

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1. Introduction to Company

1.1 Volkswagen: The Group

The Volkswagen Group with its headquarters in Wolfsburg is one of the world’s leading

automobile manufacturers and the largest carmaker in Europe. In 2010, the Group

increased the number of vehicles delivered to customers to 7.203 million (2009: 6.336

million), corresponding to a 11.4 percent share of the world passenger car market.

In Western Europe just over one in five new cars (21.0 percent) comes from the Volkswagen Group. Group sales came in 2010 to 126.9 billion euros (2009: 105.2 billion). Profit after tax in the 2010 financial year amounted to 7.2 billion euros (2009: 0.9 billion). The Group is made up of twelve brands from seven European countries: Volkswagen Passenger Cars, Audi, SEAT, SKODA, Bentley, Bugatti, Lamborghini, Porsche, Ducati, Volkswagen Commercial Vehicles, Scania & MAN. Each brand has its own character and operates as an independent entity on the market. The

product range extends from low-consumption small cars to luxury class vehicles. In the

commercial vehicle sector, the product offering spans pick-ups, buses and heavy trucks.

From the first quarter of 2011 the Group operates 62 production plants in fifteen European

countries and a further seven countries in the Americas, Asia and Africa. Around the world,

nearly 400,000 employees produce about 30,000 vehicles or are involved in vehicle-related

services each working day. The Volkswagen Group sells its vehicles in 153 countries.

It is the goal of the Group to offer attractive, safe and environmentally sound vehicles which

are competitive on an increasingly tough market and which set world standards in their

respective classes.

1.2 Volkswagen India Pvt. Ltd. - Chakan Plant Overview

Mr. John Chacko, Volkswagen Group Chief Representative India, President and Managing

Director, Volkswagen India Private Limited said, "March 31, 2009 is a landmark for

Volkswagen India Family and since then the journey has been very bright, promising and

fruitful. Allin a year and it speaks for itself how passionate and motivated we all have been

to achieve such promising challenges.‖

Volkswagen is known world over for the benchmark it has created for the quality of cars

produced. We at Volkswagen India are proud to continue the same legacy by focusing not

only on volumes but, also maintaining the same level of workmanship and the impeccable

standard of quality which is envied globally.‖

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Mr. John Chacko further added. For Volkswagen, the new production facility is a major

stepping stone towards achieving its ambitious growth targets in the Indian subcontinent.

The Pune plant covers all stages in the production process from press shop through body

shop and paint shop to final assembly. It has a maximum annual capacity of 110,000

vehicles. In addition to the Volkswagen Polo, the Pune plant also builds the Škoda Fabia.

With a total financial commitment amounting to Rs. 3,800 crores (580 million Euros), the

Volkswagen plant in Pune is the largest investment to date by a German company in India.

Volkswagen plans to employ some 2,500 people locally by the end of 2010.

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2. Volkswagen Motorsports India

2.1 History-

Making a debut in the Indian motorsport scenario.

Taking ahead more than 40 years of enriching global motorsport legacy of Volkswagen,

Volkswagen Motorsport India commenced operations with the Polo Cup India in 2010. The

series started off with a first- ever iconic race being held at Shri Shiv Chhatrapati Sports

Complex at Balewadi in Pune, the hometown of Volkswagen in India on May 30, 2010 in a

street race format.

The vast global expertise, coupled with rich dynamic history of the Group has enabled

Volkswagen Motorsport India to progress swiftly and become the best one make series in a

short span of time. The Volkswagen Polo R Cup is enhancing awareness as well as

underlining the technological advancement and power of the Volkswagen Polo in India.

Volkswagen Polo R Cup is of significant importance from the perspective of the motorsport

community as it provides a vital platform for the talented young racers to demonstrate their

capabilities nationally and internationally by nurturing them.

All participating cars are technically identical with the same performance making it possible

for only the most skilled drivers to leave an impact. The renowned car racing series has been

able to put a lot of emerging talent on the global map by training and exposing the young

drivers with the latest technological advancements for higher racing categories.

Figure 1 Volkswagen Polo R cup, Coimbatore

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2.2 Season 2013-

The Year of proving their mettle.

The third season saw Volkswagen Motorsport India progressing leaps and bounds in not just

circuit racing, but also in the rally world with the Customer Sport Initiative.

The Volkswagen Polo R Cup season 2013 started on a promising note with 12 new drivers

joining the brigade after a rigorous driver selection. Jeffrey Kruger, Volkswagen Polo Cup

driver from South Africa was the only international driver for the season. The season started

with the first two race weekends being organized at the Kari Motor Speedway, Coimbatore.

The latter half of the season saw 6 races at the Buddh International Circuit, Greater Noida.

By then, the heat of championship had reached its peak and the battles were getting

intense.

Figure 2 Volkswagen Polo R cup, BIC, Noida

Having missed the championship by a few points in the earlier two seasons, Rahil got third

time lucky! Rahil was sponsored by Volkswagen Motorsport India to be a part of the JK Tyre

FB02 season 2014, a premium single-seater racing series and a chance to drive as a guest

driver in one of the rounds of Volkswagen Scirocco R Cup, Germany. Prashanth Tharani had

to settle with overall second in the championship, followed by Angad Singh Matharoo. Yatin

Magu was awarded as the Volkswagen Polo R Cup Junior Champion 2013. Yatin was given a

fully sponsored seat in Volkswagen Polo R Cup 2014.

For being the most successful driver in season 2013, Jeffrey Kruger was awarded as the ‘Star

of Volkswagen Polo R Cup 2013’ and was sponsored to race the 2014 season of Volkswagen

Castrol Golf Cup, Poland.

Talking of the Volkswagen Motorsport India Customer Sport Initiative, Volkswagen Polo rally

cars proved their mettle in their debut year and won many rallies through the 2013 season

of Indian National Rally Championship (INRC).

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INRC 1600 Championship was also won by a Volkswagen Polo rally car driver. Also, the

season saw a factory-prepared Volkswagen Polo R2 car being tested during the INRC K1000

rally in Bangalore by APRC Champion Karamjit Singh. And for the first time in the history of

rallies in India, the fans saw a diesel rally car when the Volkswagen Polo TDI rally car hit the

track in INRC Coffee Day rally in Chikmagalur.

2.3 Season 2014 -

The year of surprises

Figure 3 Volkswagen Polo cup car

The season started with driver selection at the Kari Motor Speedway in the month of March,

entertained thousands in Coimbatore and Greater Noida and set new standards with a

record presence of spectators at a motorsport event in the country. The last race was at

Buddh International Circuit, Greater Noida on December 14, 2014.

Karthik Tharani from Chennai sealed the Volkswagen Polo R Cup 2014 Championship with a

total of 358 points. Karthik joined the Volkswagen Motorsport India family last year and

raced in the junior category of Volkswagen Polo R Cup 2013 with his elder brother

Prashanth Tharani.

As the tradition goes, the Overall Volkswagen Polo R Cup 2014 Champion will be sponsored

by Volkswagen Motorsport India to race the upcoming season in the JK Tyre FB02 category,

a premium single-seater racing series organized by JK Tyre Motorsport. He will also be sent

as a guest driver to one of the round of the Volkswagen Castrol Golf Cup, Poland.

Volkswagen Polo R Cup 2014 Junior Champion will be sponsored by Volkswagen Motorsport

India to race the 2015 season of racing program organized by us.

Volkswagen Motorsport India’s Customer Sport Initiative had another successful year with

an increase in the number of Volkswagen Polo rally cars in the Indian Rally Championship.

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2.4 Volkswagen Vento Cup 2015 -

(A new era)

Volkswagen Motorsport India entered the Indian racing scenario back in 2010 as a part of

the famed JK Tyre National Racing Championship with the first one-make series of touring

cars – the Polo Cup. After five years of nurturing young and talented racing drivers in India

and promoting them to the next level of racing, Volkswagen Motorsport India makes a shift

to a Vento Cup commencing from the competitive season of 2015.

Based on the same lines as that of Polo R Cup, Vento Cup will serve as a one-make series

with equally prepared cars being given to selected racing drivers for the entire season. The

racing competition would thus boil down to drivers’ skills where they would have to defeat

the others in equally paced machines. Drivers for the Vento Cup 2015 were selected

through an intensive selection programme. Once selected, the drivers will then be trained

further and would be prepared to compete in races that will be conducted as a part of the

18th JK Tyre Racing Championship.

The Vento Cup race cars prepared by Volkswagen Motorsport India for the series will be

based on the Volkswagen Vento production cars. These cars will have higher performance

derived from a 1.4-litre TSI engine mated with a six-speed DSG gearbox producing maximum

power of 180 PS and maximum torque of 250 Nm. The cars will be equipped with all the

safety features as prescribed by FIA such as roll-cage, racing seat, six-point harness, fire

extinguisher etc.

Figure 4 Race Vento

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3. Projects

3.1 Side Jack for a Rally car

1. Requirements –

I. Should lift the car from the ground by at least 15cm (150mm).

II. Should have simple and efficient mechanism that can raise the car by 4-5mm per

crank of the handle.

III. Should have an efficient load carrying capacity or the corner weight of the car.

IV. Should be lightweight and compact, that makes it easier to carry in a rally car

without affecting weight of the car.

V. At last it should be easier to manufacture.

2. Market Research–

Before progressing towards the design, market research was performed to get a better idea

of different designs that existed in the market of the similar product and deriving out

efficient mechanism to make the product cost effective.

3. The Design–

Before modelling the product in solidworks, calculations needed to be performed to ensure

efficient mechanism of the jack without any failure and meeting all above stated

requirements.

I. Power screw calculations –

A 400mm long power screw was selected having a pitch of 5mm so that with one revolution

of the screw the load attached to the screw was raised by atleast 5mm. The shaft diameter

was chosen to be 20mm.

II. Gearing calculations –

Bevel gear was selected for the cranking mechanism as it is easier to manufacture and small

set of gears can provide an efficient mechanism. The gearing ratio was set to be 1:1 having

no of teeth’s on both the gears as 12.

III. Modeling into solidworks –

The final and last part of the project was modeling in solidworks and following the design to

manufacture methodology. Various components were designed using solidworks part

design feature and were assembled using assembly feature of solidworks.

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Figure 5 Side Jack assembly

Figure 6 Gear housing

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Figure 7 Area for side jack attachment on a rally car

Figure 8 Side Jack attachment

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4. Analysis of the attachment-

Stress Analysis- A stress analysis of the attachment showed a peak von Mises stress of

9.467e+007 N/m^2

Displacement Plot- A maximum displacement of 0.16mm was observed ( red region).

Factor of safety plot- The fos of the attachment was 3.7 which was considered satisfactory as per

design requirement.

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Screwed shaft (Power screw)- The screwed shaft was designed having a pitch of 6mm and was made

400mm long as per design requirement.

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5. Components Designed

5.1 Underbody bracket

It acts as an underbody shield used on off-road vehicles and lowered vehicles such as

Volkswagen polo rally car to prevent damage to the underside when contact is made with

the ground.

5.2 Bumper bracket

In the event of a low-speed front- or rear-end collision, the bumper shields the rest of the

vehicle from damage by receiving the brunt of the impact. Bumper bracket attaches bumper

to main body or the chassis of the car.

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5.2 Damper spacer

A damper spacer is used to space damper from mounts for correct positioning.

Fig: Damper spacer right

Fig: Damper spacer left

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5.3 Exhaust manifold flange gasket

A gasket is a mechanical seal which fills the space between two or more mating surfaces,

generally to prevent leakage from or into the joined objects while under compression.

5.4 Catalytic converter flange and Exhaust flange

A flange is an external or internal ridge, or rim (lip), for strength, as the flange of an iron

beam such as an I-beam or a T-beam; or for attachment to another object, as the flange on

the end of a pipe, steam cylinder, etc. An exhaust flange is a device used to attach an

exhaust pipe to an exhaust manifold or another piece of exhaust pipe.

A catalytic converter is a vehicle emissions control device that converts toxic pollutants in

exhaust gas to less toxic pollutants by catalyzing a redox reaction (oxidation or reduction).

Catalytic converters are used with internal combustion engines fueled by either petrol

(gasoline) or diesel—including lean-burn engines.

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