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Design, Analysis and fabrication of ATV (All Terrain Vehicle) for the event BAJA organised by SAE.
The document provides specifications and design details for a formula-style racing vehicle. It includes dimensions, materials used, analysis of various components like the roll cage, brakes, suspension, and steering. Analysis of the roll cage shows safety factors meet requirements. Suspension design was optimized through iteration. The braking system was designed to meet performance targets. Cost analysis showed largest expenses were the powertrain and suspension systems. The project plan involves various team members focusing on different vehicle subsystems and includes failure mode considerations.
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Design, Analysis and fabrication of ATV (All Terrain Vehicle) for the event BAJA organised by SAE.
- 1. BEANT COLLEGE OFENGINEERING & TECHNOLOGY, GURDASPUR (GOVT.) TEAM ID : 16190
- 2. SPECIFICATION VALUES Overall Length2447.20mm Overall width 1828.80mm Front track width 1470 mm Rear track width 1550 mm Wheel base 1850 mm Ground clearance 297 mm Wheels- Front & rear 22*12*7 & 22*12*10 inches Maximum speed 55.6 km/hr Maximum acceleration 7.4 m/s² Gradabilty % 86.5 % Stopping distance 19.4 m (40 km/hr) Kerb weight 190 kg Ratio FAW & RAW 45:55 OVERALL VEHICLE DETAILS
- 3. Materials AISI 1018AISI 4130 AISI 1020 Availability 4 3 2 Strength 3 4 4 Cost 4 2 3 Weight 3 4 4 Total 14 13 13 Material used AISI 1018 Yield strength 365 MPa Tensile strength 440 MPa Elongation 15% Outer diameter 25.4 mm Wall thickness 3 mm Over all length 2083.6 mm Max. width 718 mm Weight 54 Kg Material selection Ergonomics Related to Cockpit : • Cockpit is designed in such a way that driver can exit within 5 seconds in an emergency . • RRH is given an angle of 15 deg. To give a good sitting posture to the driver. • Front bracing members are adjusted in a such way to give a wider view of vision. • Side impact members are designed to protect the driver from external threats. Carbon 0.18 % Iron 98.8 % Manganese 0.6 % Sulphur 0.05 % Chemical Composition : Welding used for the manufacturing of the roll cage is MIG welding . Due to its lesser cost and good strength .
- 4. Front impactforce - 24000 N (8.6G ) Max. stress - 184 MPa Deformation - 3.227 mm Factor of safety – 1.98 Rear impact force - 24000 N (8.6G) Max stress -293 MPa Deformation – 3.06 mm Factor of safety - 1.24 Roll over force - 2774 N (1G ) Max stress – 157 MPa Deformation – 6.4 mm Factor of safety - 2.32 Side impact force - 11928.2 N (4.3G) Max stress - 302 MPa Deformation – 3.9 mm Factor of safety - 1.21 Paramete r Case I Case II Case III Size of Mesh (Units) 20 10 8 No. Of nodes 219584 434629 485534 No. of Elements 133446 236481 253079 Max value of Von-Misses Stress (MPa) 225.62 285.89 290 Percentage Error 52.27 29.31 1.8 So we have selected the mesh size = 8 Because its Percentage error is less than 5 % after performing iteration .
- 5. SUSPENSION DESIGN Type ofSuspension (Front And Rear) - INWARD CONVERGING TRANSVERSE DOUBLE WISHBONE CHARACTERSTICS FRONT REAR GROUND CLEARANCE (m) .297 .315 ROLL CENTER HEIGHT (m) .231 .281 CAMBER (deg) -1.21 -1.50 CASTER (deg) 3.18 3.18 KPI (deg) 12.53 3.18 MOTION RATIO .8 .9 WHEEL RATE (N/mm) 9.645 15.612 SPRING STIFFNESS (N/mm) 15.07 19.274 NATURAL FREQUENCY (Hz) 2.41 2.46 RIDE FREQUENCY (Hz) 1.96 2.27 ROLL STIFFNESS(Nm/deg) 202.54 327.15 CG Height (m) – .505 Scrub Radius (m)- .067 Sprung mass (kg) – 204 Unsprung mass (kg)- 76 Material Used – 4130 MAX . VON MISES STRESS-175Mpa FOS-2.62 Material Used- 4130 MAX. VON MISES STRESS- 148Mpa FOS- 3.1 Bump travel (front)- 7inch Bump travel (rear)- 6inch Droop travel (front)- 5inch Droop travel (rear)- 4inch
- 6. BRAKES Disc Brakes X-split brake circuit with master cylinder of Maruti 800 Bosch tandem cylinder (OEM) having bore diameter ¾ Inch and piston area of 0.4393 sq. Inch. Discs of Maruti Zen is used for front wheels and TVS Apache RTR 180 is used for rear wheels and calliper of respective discs are used. For Brake fluid DOT 3 is taken. SPECIFICATIONS VALUE FRONT DISC DIAMETER 182mm REAR DISC DIAMETER 270mm FRONT CALLIPER PISTON 50mm REAR CALLIPER PISTON 32mm BRAKE FORCE 2058N PEDAL FORCE 70lbs DECELERATION 7.35m/s² PEDAL RATIO 6:1 FRONT BRAKING TORQUE 189.04Nm REAR BRAKING TORQUE 280.36Nm CALLIPER PAD FRICTION COEFFICIENT(FRONT WHEEL) 0.08 CALLIPER PAD FRICTION COEFFICIENT(REAR WHEEL) 0.29 SPECIFICATIONS VALUE FRONT CLAMPING FORCE 12.86KN REAR CLAMPING FORCE 3.548KN CYLINDER PRESSURE 6.59MPa MEAN BRAKING RADIUS 91.85mm WEIGHT TRANSFER 552.814N STOPPING DISTANCE 19.4m(40km/hr) STOPPING TIME 1.75s(40km/hr)
- 7. STEERING SYSTEM Over steer Ackerman% - 80 Steering angle - inside - 40.51 (deg.) outside - 26.98 (deg.) Turning circle radius – 2901.2mm STEERING GEAR – R & P RHD (MARUTI SUZUKI 800) Rack travel – 120mm Turns lock to lock, rev. – 3.25 Steering ratio – 12:1 OBJ center distance - 110mm Length of Tie rod – 397mm Length of steer arm – 86.9 mm STEERING COLUMN Collapsible Without power assist LOTUS STEERING ANALYSIS Steer Toe Ackerman Turning circle Travel angle (%) radius (mm) {SAE} (mm) (deg.) 45.00 38.00 81.70 2979.55 30.00 22.70 71.53 4955.39 15.00 10.57 67.35 10418.21 0.00 0 66.16 0 -15.00 -9.62 67.35 10418.21 -30.00 -18.63 71.53 4955.39 -45.00 -27.25 81.70 2979.55 STEERING WHEEL Steering wheel diameter -390mm Steering wheel torque – 58.5Nm Wheel Geometry
- 8. POWER TRAIN • ENGINESPECIFICATIONS • Briggs and Stratton • 305CC • 10HP • 19Nm at 2800 rpm Overall gear ratios Tractive force (N-m) Maximum velocity km/hr Maximum acceleration m/(sec) ² Gradability %age 37.5:1 2294 9.4 7.4 86.5 25:1 1529 13.5 4.7 57.6 12.5:1 764.6 28.2 2.0 28.8 6.25:1 382 55.6 0.6 14.4 • TCVT= 14.5 lb-ft * (12 in/ 1 ft) * (3/1) * 0.83 = 433 in-lb =48.9Nm • Factor of safety for shaft is 4 • For tire diameter =22inch the maximum velocity attained by vehicle is 55.6 km/hr • N= Transmission efficiency = 0.85 • Torque on the wheel=420ft-lb = 569.4Nm • 12.5:1 Gearbox is used • TRANSMISSION : CVT COUPLED WITH MAHINDRA ALPHA GEAR BOX • LAYOUT OF ENGINE , CVT AND GEAR BOX
- 9. COST ANALYSIS &WEIGHT DISTRIBUTION 26.50% 20.50% 19% 6.30% 12.60% 15.14% COST ANALYSIS POWER TRAIN SUSPENSION & STEERING ROLL CAGE BRAKING WHEEL TIRE SAE REGISTRATI ON 24.28% 19.28% 19.40%13.92% 23.00% WEIGHT DISTRIBUTION TRANSMISS ION & BRAKING SUSPENSIO N & STEERING ROLL CAGE WHEEL & TIRE DRIVER
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- 11. Part Function FailureModels Precaution Validation Accomplishment Roll Cage Basic Soul Of Vehicle And To Protect The Driver When Material Reaches To Ultimate Stress Value. Use Of AISI 1018 Steel Having Yield Strength Value Equal 370 Mpa. Welding Test Universal Testing Machine ENGINE To Generate Power Spark Plug Failure/Improper Functioning Of Old Filters. Regular Check Of Spark Plug & Filter Change. Fuel Leak Test Vehicle Should Be Tested In Various Road Condition TRANSMIS- SION To Transmit Power From Engine To Wheels Improper Lubrication/Unexp ected Load. Use Of ISO Grade Oils . Speed And Acceleration Test Road Test SUSPENSION To Absorbs Shocks And To Give A Smooth Drive When Coil Reaches To Solid Length. Proper Calculation And Assumption In Designing. Wheel Travel Inch Tape BRAKES To Reduce The Speed When Required And Emergency Stop Circuit Failure Due To Leakage Worn Out Break Pads. Bleeding Of Vehicle’s Break Before Every Run, Checking And Replacement. Breaking Test Road Test WHEELS To Provide Good Traction Inappropriate Air Pressure/Puncture Tire. Checking Of Air Pressure At Every Refuel Backup Extra. Tire Air Pressure Air Pressure Gauge DESIGN FAILURE MODE EFFECTS ANALYSIS AND VALIDATION PLAN
- 12. TEAM COMPOSITION &COLLEGE FACILITIES TEAM STRATEGY FACULTY ADVISOR : SANDEEP GANDOTRA DEPARTMENTS TEAM MEMBERS 1. ROLL CAGE ARSHDEEP SINGH, AMAN RANA, VINAY KUMAR (Captain) ,LOVY MINHAS, SAEED AKHTAR, SACHIN, SATNAM SINGH 2. TRANSMISSION ANUJ BHARDWAJ, SHIVAM BHARDWAJ,AMARJEET GULERIA, NAVJEET SINGH, KASHISH MAHAJAN, RAKESH ,SHAMSHER SINGH,VARUN SHARMA 3. SUSPENSION ANSHUL SHARMA, ABHISHEK THAKUR, VINAY KUMAR, ANUBHAV MAHESHWARI, ABHINAV KUMAR, NITISH PANDEY, SATISH 4. BRAKING GAGANDEEP SINGH, ANUJ BHARDWAJ 5. STEERING AMAN RANA, ARSHDEEP SINGH, AMARJEET GULERIA 6. DRAFTING & ANALYSIS KRISHNA KHOSLA,JATIN SARINE 7. MANAGEMENT ANUBHAV MAHESHWARI,SHAMSHER SINGH,UTKARSH COLLEGE FACILITIES For Roll Cage , Each and every equipment available in welding shop. For Custom Knuckle , requirements are available in Carpentry , Foundry and machine shop. For Seat Installation and Sheet Covering of vehicle , equipments are available in welding and sheet metal shop. For clamping of Wishbones , each and every requirements are available in Central Workshop. For Assembly and Installation of all other parts of vehicle, requirements are available in Central Workshop.