1. The document outlines the design specifications and rules for an all-terrain vehicle (ATV) racing competition. It includes requirements for dimensions, materials, driver safety, speeds, and allowed pre-fabricated parts. 2. Detailed specifications are provided for the vehicle's 10HP engine, roll cage made of chromoly steel, dimensions, weights, double wishbone front and rear suspension systems, rack and pinion steering, disc brakes, and 4-speed transmission. 3. Performance targets include minimum weight, desirable traction, maximum gradeability, reduced rolling resistance, and optimized braking. 2D drawings and 3D models illustrate the vehicle design.

1. 1.
Flying High…

2. RULEBOOK 2.
1.) Width: 162 cm (64 in) at the widest point with the wheels pointing forward at static ride height.
Length: Unrestricted.
2.) A steel shape with bending stiffness and bending strength exceeding that of circular steel that of circular steel
tubing with an outside diameter of 25 mm (1 in.) and a wall thickness of 3 mm (0.120 in.) and a carbon content of
0.18%.
3.) The driver’s helmet shall have 152 mm (6 in.) clearance, while the driver’s
shoulders, torso, hips, thighs, knees, arms, elbows, and hands shall have 76 mm (3 in.) clearance.
4.) Roll Cage Structure dimensions are considered.
5.) The cockpit must be designed to (Considerations: Driver Exit Time, Firewall, Belly Pan, Leg And Foot Shielding ),
(i) protect the driver and
(ii) permit easy driver exit in an emergency.
6.) List of pre-fabricated parts allowed are – shock absorbers, spring, brake drum, brake disc, brake calipers and
brake holding assembly, master cylinder, steering gear box, steering column, steering wheel, wheel rims & tires, seat
frame tie rod ends.
7.) The brake system must be capable of locking ALL FOUR wheels, both in a static condition as well as from speed
on pavement AND on unpaved surfaces.
8.) All rotating parts such as belts, chains, and sprockets that rotate at the rate of the drive axle(s) or faster, must be
shielded to prevent injury to the driver or bystanders should the component fly apart due to centrifugaL
force.
9.) Maximum speed of the vehicle on a plain terrain is recommended to be no more than 60 km/h at top gear.
10.) Easy reach to control board, gear shifter and hand brake.

3. SPECIFICATIONS 3.
ENGINE 10 HP, OHV TYPE, B & S ENGINE
ROLLCAGE
 Material : AISI 4130 (Chromo Moly
Steel)
DIMENSIONS &
WEIGHT
Overall Dimensions :
 Overall Weight : 275 kg including Driver
Track width :
 Front : 54 inches
 Rear : 52 inches
Centre of Gravity : 33.6 inches from front
axle and 14 inches from ground
STEERING
 Geometry : Ackermann
 Type Of Steering : Rack And Pinion
 Turning Radius : 2.4 m
SUSPENSION
 Front : Double A-Arm (7 inches) Travel
Coiled Spring
 Rear : MacPherson (7 inches) Travel,
Coiled Spring
 Ground Clearance : 10.72 inches
TRANSMISSION
 Type : 4 Speed Constant Mesh
 Top Speed : 56.93 Km/h
 Gear Configuration : 4+R
 Direct Coupling
WHEELS
 Front : 23x8-12
 Rear : 23x8-12
BRAKES
 Type : All Disc,
 Diagonal Split Circuit
BATTERY  12V, 44 Ah
 Overall Performance Targets
 Minimum weight achieved through
material selection.
 Desirable traction & maximum
gradeability through suspension geometry
& wheel selection.
 Reduction of rolling resistance by
improving steering ability.
 Achieving optimum Braking Factor.
 To minimise jacking forces.
 To minimise body leaning at cornering.

4. 2D-3D VIEWS 4.
All dimension in inch

5. ROLLCAGE 5.
Objective: Driver’s Safety, Light Weight & Proper Spacing.
Justification:
Roll Cage mass = 32kg & Number of Weld Joints = 56.
Material Comparison:
Material Selected: AISI 4130
Welding: Tungsten inert gas (TIG)
Filler Material: ER70S-2 or ER80S-D2
Reason to select AISI 4130:
25% Elongation at break.
Better strength-to-weight ratio.
Section Material Diameter (in) Wall Thickness (in) Bending Stiffness (lb.in2) Bending Strength (lb.in)
Round AISI 1018 1 0.118 752568.27 2721.41
Round AISI 4130 1.125 0.065 824174.07 3112.93
Square AISI 4130 1 0.065 1057078.42 4491.69
Analysis Front Impact Side impact Rear impact Roll over Bump Impact Torsional
g’s 6 3 3 4 3 2
Max. Equivalent Stress
(Pa)
1.986e8 1.0727e8 8.44 e7 7.44e7 1.244e8 1.650e8
Max. Deformation(mm) 1.1mm 0.5mm 0.3mm 0.28 mm 1.6mm 0.8mm
Factor of safety 2.22 4.11 2.22 5.91 3.53 2.66

6. FEA 6.
Front
Impact
Side
Impact
Rear
Impact
Bump
Impact
Torsional
Rollover

7. ERGONOMICS 7.
Objective :
To enhance performance and productivity of driver.
 Prevent fatigue and injury.
Safety Points :
• 5 Point Safety Harness
• Neck Restraint (360ᵒ) & Arm Restraint
•Rubber Padding on Roll Cage Pipes
• Fire Extinguishers
Safety Clearances :
Head Clearance: 7 inch
Side Clearance: 6 inch
Back Clearance: 3.5 inch
Front Clearance: 7 inch
Sitting Layout & Ease of Egress :
 Steering wheel fully up and fully forward.
 Seat height at its lowest.
 Cushion tilted so that front edge is in lowest
position.
 Back rest approximately 30 degrees
reclined from vertical.
 Seat fully rearwards.
Driver can move the seat forward until
he can easily push the pedals through his
full range with his whole foot, not just
with his toes.
Vision and control:
Display panel is in full view
 Driver is able to see 3 inch over the top of the steering
wheel.
Easy reach to control board, gear shifter and hand
brake.
PVC Prototype
Driver’s Vision

8. Targets : To reduce impact shocks , To maintain traction between wheel and ground, To hold wheels in alignment.
Geometry selection: Front suspension double wishbone rear suspension - Macpherson strut
Static condition:
Vehicle Weight= 3433.5 N
40% distribution in front = 1373.4 N
60% distribution in rear =2060 N
Dynamic loading condition:
Assuming projectile motion of ATV,
Velocity ‘V’ =55kmph=15.277m/s
Inclination angle ‘Θ’= 25°
Dynamic load on tire:
Dynamic load on front single tire:
Load x a = 350x0.5x76.38/2=6683.25N
Dynamic load on rear single tire:
Load x a = 350x0.5x61.108/2=5346.951N
Parameter Load Deflection
Front 6683.25 N 125 mm
Rear 5346.95 N 124 mm
Rear
suspension
Front
suspension
SUSPENSION- I 8.

9. Spring material and design –
Material Properties:
Material Selected : ASTM A228,Ultimate Tensile Strength : 1083 MPa ,Modulus of rigidity (G) : 79000MPa
Shear stress for front (τf)=854.92 N/mm2 and for rear (τr)= 802.73 N/mm2. FORMULA USED
Geometric Parameters:
Roll centre height 9.87 inch
Motion ratio .7
Wheel travel 7 inch
Deflection 125 mm
Roll centre height 11 inch
Motion ratio .9
Wheel travel 7 inch
Deflection 124 mm
Front: Rear:
SUSPENSION - II 9.

10. Cornering Performance:
Assuming a condition of a left hand turn:
Velocity ‘v’: 56 kmph = 51.31 ft/sec,
Roadway bank angle = -10 deg
Radius of vehicle path horizontally ‘R’ = -210 ft
For which:
Suspension Roll Stiffness:
Front & rear
=293.54 lb-ft/deg Rear
=211.35 lb-ft/deg
Horizontal Lateral Acceleration: = -0.389g.
Lateral Acceleration (car axis):
=-0.209g.
Effective Weight (Banking):
= 920.81 lbs
For front: 368.30 lbs & rear: 552.46lbs.
Roll Over Gradient: =-2.45 deg/g..
Roll angle: = 0.535 deg.
Lateral load transfer due to banking:
For front: - 46.34 lbs.
For rear: -48.25 lbs.
Ride rate:
For front: = 6.62 lb/inch
For rear: = 6.89 lb/inch.
Ride frequency:
For front: = 36 cpm
For rear: =30.41 cpm
SUSPENSION COMPONENTS:
Knuckle : We will fabricate, because of desired geometry.
Material using for it will be aluminum 7075 t6.
Suspension arms : Fabricating our own using roll cage
material AISI 4130 chrmomoly steel .
Spring and shocks : Using pre fabricated parts
as it will reduce cost and have greater reliability .
Joints: Using ball joints because of its more movement in less
space.
SUSPENSION - III 10.

11. STEERING - I 11.
• Target: To attain minimum possible turning radius according to our dimension to get better
maneuverability, and get quick response steer.
• Turning radius:
• Inner wheel lock= 35ο Outer wheel lock= 22.68ο
i) Turning radius for inner front wheel = 94.63 inch = 2.40 m
ii) Turning radius for outer front wheel = 142.23 inch= 3.61 m
iii) Turning radius for inner rear wheel = 76.97 inch= 1.95 m
iv) Turning radius for outer rear wheel = 131 inch= 3.32 m
• Turning radius w.r.t C.G = 108.66 inch = 2.76 m
• Steering mechanism: Rack and Pinion steering mechanism is used as it provides quick response for
steering and light in weight .
• ( steering mechanism of “TATA IRIS” is preferable as it have turning radius of 3.50 m)
• Drive: Front axle Steering.
• Steering wheel rotation: steering wheel 2.33 rotation to lock the wheel at 35ο
• Ackerman geometry: 64% minimum possible Ackerman
• Ackerman arm angle: King pin to king pin distance 48 inch
• Ackerman arm angle= 30.11ο
• Ackerman arm radius: 13.87 inch
• Tie rod length: 28.30 inch
• Position of tie rod: 12 inch behind the wheel track.
• Steering wheel angle: lock to centre= 318ο

12. STEERING - II 12.
• Return ability
Mv = -(Fzl + Fzr) (d sin δ)sin Ѱ+ (Fzl -Fzr) (d cosδ) sinν
= 2.230Nm (when δ is steered negative ) &
= -0.8827Nm (when δ is steered positive )
• Static Camber, Υ̻: 0.75
• Camber angle equation :
Υ=Υ̻+ Ѱ+ −1[(sin Ѱ) x co s δ] + −1[(sinν) x sin δ] -180ο
• Caster ,ν: 5ο
• Toe in: 3mm
• Steering angle inclination:

13. BRAKES - I 13.
TARGET: To design an efficient brake assembly by which we can achieve minimum pedal force, minimum
stopping distance, with maximum braking torque.
BRAKE SELECT: Disc brake of 200 mm diameter, diagonal split circuit.
DIAGONAL SPLIT CIRCUIT
CALCULATIONS:
W = 350 x 9.81 = 3433.5 N
µ = 0.7
l = 56 inches
Pedal Force = 100 N
Fbp = Fd x [ L2 / L1 ]
Brake Pedal Force = 550 N
Pmc = [ Fbp / Amc ]
Pressure at master cylinder = 2.73 x 106 N/m2
Pcal = Pmc
Fclamp = Pcal x Acal
Fclamp = 2631.539682 N
Fclamp = Fcal x 2
Total force at caliper = 5263.079364 N
Ffriction = Fclamp x µbp
Total friction force at Caliper = 2105.231746 N
Tr = Ffriction x Reff
Torque at rotor = 202.8917095 N-m
Torque at rotor = Torque at wheel
Ftire = ( Tt / Rt )
Ftire = 694.5967459 N
Ftotal = 694.5967459 x 4
Total braking force at all wheels = 2778.386984 N

14. BRAKES - II 14.
av = Ftotal / mv
Deceleration = 7.938248526 m/sec2
V = u – at
Stopping Time = 1.994562564 sec
V2 = u2 – (2as)
Stopping distance = 15.78962212 m
Total weight of the vehicle = 350 Kg = 3433.5 N
Total front axle load (in static condition) = 1373.4 N
Total rear axle load (in static condition) = 2060.1 N
Dynamic load transfer = 793.8 N
Braking Efficiency (η) = (0.4 x u2) /15.789
(η) = 82.31 %
In any panic condition we can this way make
the brake go actuated and make the vehicle
to get to a full stop safely in approximately
4 m distance.
Results:
Stopping Distance: S = 15.78962212 m
Deceleration: av = 7.938248526 m/sec2
Stopping Time: t = 1.994562564 sec
Braking Efficiency: η = 82.31 %

15. POWERTRAIN - I 15.
Targets/Design Considerations :
Suitable gear ratio to achieve
Maximum speed 60 km/h.
Max. initial acceleration > 6m/sec2
Grade of 30 degrees.
Smooth and easy power flow
(Direct coupling).
Wheel Selection :
Front Carlisle 23 x 8 – 12
Rear Carlisle 23 x 8 – 12
VEHICLE PERFORMANCE
considered Mahindra ALFA

16. POWERTRAIN - II 16.
Basic Calculations :
Maximum Vehicle Speed = (2*π*3800*.2921*60)/(1000*7.35) = 56.93 km/h
Maximum Acceleration = 550*32.2*10/12.11*661.38 = 6.7 m/s2
Torque at Clutch = Te-Ie αe = 19.04 Nm
Maximum Torque Output to driveshaft / wheels = (19.04-.0000001034*18096.4)*31.45 = 598.74 Nm
Maximum Tractive Force = 19.2*.85*31.45/.2921 = 1757.15 N [Taking transmission efficiency = 85%]
Gradeabilty or Max Gradient = 59.193 % = α = 30.6225 degrees. Tractive Curve
Adapter & Coupler : The crankshaft of the engine has diameter of
25.4 mm,a keyway for 1” square key, whereas splines are at
the gearbox side of diameter of 20 mm at. Hence, an adapter has
been designed with an internal keyway on the engine side and external
splines on the gearbox side. The axial length of the designed Coupler
is kept to be 42 mm
Designed Adapter Creo Image of Coupler Assembly Powertrain Model
Mountings :
The engine is to be mounted in the rear of the roll cage on pipes of rectangular cross section using rubber bushings.
For the gearbox mounting, the standard mounting bracket is to be utilized.

17. COST & WEIGHT ANALYSIS 17.
ENGINE
8% Rollcage
12%
Transmission
8%
Brakes
5%
Steering
2%
Suspension
22%
Wheels
12%
Accesories etc.
8%
Misc.
2%
Driver
21%
Weight (in Kg)
S. No. Name of System Components of the System Cost in INR
1. TRANSMISSION
ENGINE, GEARBOX, HALF SHAFTS,
SILENCER MUFFLER, ETC.
45,000 INR
2. STEERING
RACK AND PINION, STEERING WHEEL, TIE
RODS, BUSHINGS, ETC.
5,225 INR
3. BRAKES
DISCS, CALLIPERS, FLUID LINES, BRAKE
PADS, BRAKE FLUID,HUB, ETC.
23,380 INR
4. SUSPENSION
SPRINGS, DAMPERS, A-ARMS, KNUCKLE,
ETC.
69,734 INR
5. ROLLCAGE AND MATERIAL
PIPES OF SELECTED MATERIAL,
SHEETS, WELDING ACCESORIES, ETC.
35,370 INR
6. TIRES AND RIMS WHEELS, RIMS, TIRES, ETC. 55,000 INR
7. ACCESORIES
TRANSPONDER, ELECTRICALS, BATTERY,
SPEEDOMETER, FUEL GAUGE, ETC.
13,000 INR
8. ERGONOMICS DRIVER SEAT, STEERING WHEEL, ETC. 15,000 INR
9. MISCELLANEOUS
PUTTY, PAINT, PEDALS, LEVERS, NUT,
BOLTS ETC.
7,000 INR
10. TOTAL 2,68,709INR
TOTAL WEIGHT:-
275 Kg.
Sponsorships
20%
College
Contribution
60%
Team
Contribution
20%
Financing Statistics
Rollcage &
Material
13%
Engine
11%
Transmission
6%
Brakes
9%
Steering
2%
Suspesnion
26%
Wheels &
Tires
20%
Ergonomics
5%
Accesories
5%
Miscellaneou
s
3%
Cost (in INR)

18. PLANNING-I 18.
14/04/2014 29/05/2014 13/07/2014 27/08/2014 11/10/2014 25/11/2014 09/01/2015 23/02/2015 09/04/2015
Registration
Task allocation
Market analysis
Frame design
Design & Calculation of Components
Rectifying the errors
Full vehicle analysis
Virtual BAJA 2015
Ordering and delivering of Engine
Ordering and delivering of pipe
Rollcage Fabrication
Final Design Report Submission
Engine and Transmission
Brake assembly
Examination Break
Checking Vehicle under BAJA 2015 norms
Vehicle testing and Validation
SAEINDIA BAJA 2015
PLANNED INNOVATIONS :-
Vehicle Sensor
Impact Attenuator
Central Tire Inflation System
PROJECT PLAN

19. PLANNING - II 19.
Process Step
Potential failure
mode
Potential failure
effect
S Potential causes O
Current
process control
D R.P.N Actions taken
New
S O D
R.P.N
.
Roll-Cage
Breakage of weld
joints.
Breakage of roll
cage.
8 Improper welding 4
Using TIG
welding.
6 192
Rewelding , Anti-
corrosion coating
8 2 6 96
Suspension
Improper
distribution of load,
improper design
Suspension too
flexible/stiff and
sagging of spring
6
Improper
suspension
geometry.
4
Keeping in mind
load distribution and
various constraints.
8 192
Proper design of
suspension geometry
and analysis of load.
6 3 8 144
Brake Discs Slip Failure of brakes
9
Loss of Friction
between calliper
pads and the disc
4 N/A 8 288
Proper Selection of
the Discs and
Callipers with the
ease of braking.
5 2 8 80
Steering Breaking of tie rod.
Loss of
maneuverability
9 Excessive load. 5
Using high
strength material.
3 135 Replacing tie-rod 9 2 3 35
Engine
Breakage of
connecting rod due
to Knocking
Loss of power,
Immobility
6
Knocking and
detonation.
5 Using proper fuel. 4 120 N/A 9 4 4 50
Transmission
Breakage of half
shafts, adapter etc.
Dynamic failure,
vehicle does not
move
8
Impact load on
coupler
4
Installation of
bearings in
knuckles.
5 160 Replacing half shafts 8 2 5 80
SYSTEM: BAJA VEHICLE TEAM NAME: PHALCONS
No. Action Taken Description Acceptance Criteria Person
Responsible
Test Resource Sample
Qnty/ Level
Start Date End Date
1. Material Test Tensile Test Tensile Strength should be
460 Mpa.
Amit Malu UTM 1 08-05-2014 09-05-2014
2. Welding Test Tensile test of
welded sample.
Tensile strength should be
near about 80% of parent
material.
Amit Malu UTM 1 11-05-2014 12-05-2014
3. Brake Test Vehicle run at 55
Kmph and brake is
applied.
1. Stopping distance 4m.
2. All wheels should lock
at same time.
Sarang Korde Brake Test Track 1 05-01-2015 08-01-2015
4. Steering Test Turning the vehicle
with full steer.
Turning Radius should be
less than 2m.
Ashish Singh Figure 'O' Test at College
Ground
1 09-01-2015 10-01-2015
5. Acceleration Test Accelerating the
vehicle from rest on
100 ft track.
Distance should be
covered in 3 sec.
Sarang Korde 100 ft Acceleration test
track.
1 11-01-2015 15-01-2015
6. Mock Endurance
Test
Drive the vehicle for
atleast 5 hours
Complete the test without
any failure.
Suyash Garg College Ground 1 16-01-2015 25-01-2015
DFMEA
DVP

20. COLLEGE FACILITIES - I 20.
Roll cage TIG Welding , Electric arc
welding, Pipe bending
machine
Suspension Marking Gauges ,
Welding
Steering Hand tool kit with
precision gauges
Hub , spindles , upright ,
universal joints , tie rods
Lathe machine , CNC
machine
Other parts Milling machine
Finishing Hand grinding machine,
Emery papers
Electrical Multimeter, Soldering
machine, Wire cutting to
Facilities required for Manufacturing Vehicle College Facilities
 MACHINING
Center Lathe
Universal Milling
 Machine
Grinding Machine
Drilling Machine
Shaper machine
 WELDING
TIG welding machine
Electric arc welding machine
 MANUFACTURING MACHINES :
Milling Machine
 TESTING MACHINES :
Universal tensile testing machine
 EXTRA EQUIPMENTS
Paint Equipment
Hand grinder
Pipe bending
Power hack saw
Angle grinder

21. TEAM STRATEGY 21.
Faculty Advisors
Mr. KAMAL OJHA
Mr. SOHAM MUNJAL
ROLLCAGE
TRANSMISSION
STEERING
SUSPENSION
BRAKES
INNOVATION
SOURABH SAINI
RACHIT GARG
SHIVAM MISHRA
AMIT MALU
PRIYANKA DHAMANDEKAR
RAJAT SINGH SISODIYA
VAIBHAV PORWAL
ASHISH SINGH
AMIT VERMA
PRAKHAR MISHRA
SANU M.S.
TARUN TIDKE
RATNESH KHADIKAR
DEVPAL SINGH UMATH
ASHISH PATEL
SUYASH GARG
PRATEEK RATHORE
PRIYANKA KHERDEKAR
MOHIT RATHORE
TEAM CAPTAIN
SARANG KORDE
(Team Co-ordination, Rulebook Study,
Resource Management)
MARKETING
CHANDRADEEP YADAV
NIKHIL DHANAWADE
PUNIT SONI
ELECTRICALS
ACHAL KOUSHAL THANK YOU