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Automobile 4*4 vehicle data with calculation ppt
- 1. DEPARTMENT OF MECHANICALENGINEERING Presentation on FABRICATION OF ALL TERRAIN VEHICLE 4*4
- 2. INTRODUCTION WHAT IS ANATV? • It means an all terrain vehicle – which is specially fabricated for off road driving. • ATV is fabricated for very rough terrains and in general is a single person vehicle. • Fabrication process is iterative and based on several engineering and reverse engineering processes PROJECT OBJECTIVES • Design and build a safe and durable ATV for off road terrains • Optimize the ATV’s performance for speed, handling and stability • Develop reliable suspension and steering for better control and comfort • Implement an efficient powertrain and effective braking system for safety and performance • Test and validate the ATV to ensure it meets design and safety standards.
- 3. ATV’24 vs ATV’25 56inch 58 inch • Cockpit area was too large • Front gap from the front most member to driver toeas was extra and useless empty space • Rear engine compartment area was smaller and difficult to fit parts • There were two base panels to keep propeller shaft in between • Cockpit area is closely designed according to driver ergonomics • Front gap reduced so as to fit differential, steering and brakes components smartly in less area • Rear engine compartment area is kept wide and spacious to fit splash shield and other parts safely • Only one belly panel is kept thus reducing extra material and weight. 54 inch 56 inch
- 4. Lessons Learnt Previous problems • Splashshield mounting was improper as it could not avoid oil spillage. • Propeller shaft U joint was not covered with proper thickness material thus compromising driver safety • Low acceleration due to the heavy weight . • Faced problem in suspension and traction test due to the heavy weight . • Wheel size is 21*7-10 Proposed solutions in the new vehicle • Splash shield material and area of fit both are paid special attention at earliest stages. • We are now ensuring that all rotating parts are properly covered in accordance with the driver safety compliance • Targeting high vehicle performance and driver safety priority . • Wheel size is 23*7-10 is beneficial for roll over obstacle.
- 5. CHASSIS The structural frameworkof the ATV, designed to protect the driver during rollovers or impacts and provide a foundation for mounting other components like the suspension, engine, and body panels. It is crucial for the vehicle’s overall safety and structural integrity CHASSIS ROLL CAGE NAMED POINTS FRAME MEMBER • Main structural components that form the core of the roll cage. • They are responsible for the overall strength and integrity of the structure, especially in the event of a rollover or collision. • They must be designed and positioned to provide maximum protection to the driver. • These components provide additional support and reinforcement to the primary members but are not as critical in absorbing impact forces. • Enhance the rigidity and stability of the overall structure and help mount other components.
- 6. ROLL CAGE DESIGN PROPERTIESAISI 4130 AISI 1018 Yield strength 460 MPa 370 MPa Tensile strength 540 MPa 440 MPa Density (gm/cm^3) 7.85 7.87 Bending stiffness 3632.6 N/m 2763 N/m Bending moment 804.7 N-m 387.3 N/m ROLLCAGE Material Selection CHASSIS FRAME DIMENSIONS Length : 77.31in Width : 35in Height :53in Fig.: SIDE VIEW Fig.: ISOMETRIC VIEW Fig.: FRONT VIEW Fig.: TOP VIEW • Protect the driver by providing structural integrity during rollovers or collisions • Design a lightweight yet strong framework • Optimize ergonomics to ensure driver comfort, visibility, and ease of entry/exit.
- 7. POWERTRAIN ENGINE SPECIFICATION : Briggsand Stratton 10 HP OHV Vanguard Model 19 Displacement : 305cc Max power : 7.35KW @3800 Max Torque : 19.6 Nm @2800 Gear Box type Two Stage Reduction Gear type Spur Gear Gear Reduction 9.22 Gear Material EN24 CVTech CVT CVT Ratio : 0.4 to 3.1 TRANSMISSION UNIT : Engine CVT Stage 2 reduction (3.4:1) Differential (3.5:1) Wheel Stage 1 reduction (2.7:1) PERFORMANCE VALUE Max. Velocity 57 km/hr. Acceleration 5.06 m/s^2 Gradeability 51.6% Efficiency 76% • Provide efficient and reliable power delivery to the wheels • Ensure smooth and responsive acceleration across various terrains • Integrate effectively with other systems like suspension and steering for balanced vehicle dynamics
- 8. SUSPENSION Fig: H-arm Rear Fig: Doublewishbone Front LINKAGE DESIGN CG Height 540 mm Ground Clearance 351mm Roll centre height(F/R) 256.54/301.75 Motion ratios(F/R) 0.75/0.70 Wheel travel(F/R) 200/ 265 • Absorb shocks and vibrations to enhance driver comfort and minimize impact forces. • To provide all wheel independence, maintaining maximum traction, maintaining Maximum Traction. • Avoid excess rolling of the chassis. Damping coefficient 719/1109Ns/m Damping Ratio 0.52 Spring wire diameter 12mm Spring material ASTM 103 Spring diameter 58mm Spring factor of safety 2.28 Natural Frequency 1.3/1.6hz Spring Stiffness 8.878/20.864
- 9. STEERING • Provide preciseand responsive control for maneuvering • Ensure stability and predictability during high-speed and low-speed turns. • Minimize steering effort while maximizing driver feedback and comfort Track Width 54 Inch Wheel Base 56 Inch Fig.: Ackerman geometry Steering ratio 4:1 Rack Travel 99.88 mm Pinion Diameter 44.06 mm Turns(Lock to Lock) 1.44 Turn Steering angle (in) 40 deg. Steering angle (out) 24.87 deg. Column Type Fixed Wheel Diameter 300mm Ackerman angle 46.3 deg. Ackerman % 35.6 Opting for Ackermann Geometry because it is beneficial during Sharp Turning and reduces Steering Efforts. This helps in maneuverability. Considered Over-Steer geometry to achieve high Turning Circle.
- 10. BRAKES •Provide reliable andefficient stopping power. •Ensure quick vehicle control and achieve desired stopping distance. •Distribute braking force evenly to ensure all wheel locking. •Minimize brake fade and maintain performance under repeated use. Components Selection • Hydraulic disc brakes on all four wheels • TMC with double pot: Maruti800 Bosch with bore size 19.04 mm • Calliper Used : Fixed Calliper of KBX • Brake fluid : DOT 3 PARAMETER VALUE Height of center of gravity 540 mm Pedal ratio 6:1 Disc size 170/110mm Caliper bore 29 mm Total weight of vehicle 250 kg Deceleration rate 6.68m/s^2 Required torque 236 N-m(F) 122 N-m(R) Weight transfer at 40kmph 18.6% Achieved values with the selection: • Pressure: 6.38 MPa • Torque: 266.8 N-m Fig. : H-split brake circuit layout
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