This document is a presentation of the designed ATV by Team Abhedya who secured overall rank 13th out of 325 team in the India on their debut performance.

1. BAJA SAEINDIA 2014
MARATHWADA MITRA MANDAL’S
COLLEGE OF ENGINEERING,
KARVENAGAR, PUNE,
MAHARASHTRA.

2. SPECIFICATIONS, TARGETS AND 3D VIEW
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BAJA2014_TeamAbhedya_MMCOE_Pune
Specifications :
Targets For Designing BAJA 2014 Vehicle :
Provide Maximum SAFETY to Driver. Keep Minimum Manufacturing Cost.
Maintain 100 % COMPLIANCE with the Rule Book. Keep Weight as Minimum as Possible.
Weight 280-290 kg.
Maximum
Dimensions
2410x1626x1465 mm3
Drive Rear Wheel Drive
Engine 10 HP, 305 cc
Suspension
Double Wishbone &
McPherson Strut
Transmission Manual Transmission
Braking 4 Wheel Disc Brakes
Steering Rack and Pinion
3D View :

3. ROLL CAGE DESIGN
Material
AISI 1018 Steel
( Syt= 365 MPa )
Diameter of Steel Tube 25.40 mm
Thickness of Steel Tube 3 mm
Maximum Length 2410 mm
Maximum Width 915 mm
Maximum Height 1194 mm
Overall Weight 60-65 Kg
BAJA 2014 Rule Book
Material Selection
Selection of Diameter and
Thickness
Driver Ergonomics
Requirements of Other
Subsystems
Design Parameters : Specifications of Roll Cage :
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BAJA2014_TeamAbhedya_MMCOE_Pune
DUMMY
COCKPIT
( Scale : 1:1 )

4. Force 35 kN
G’s 10g
Max. Stress 233.17 MPa
Max. Deformation 4.3 mm
F.O.S. 1.57
Front Impact :
FEA REPORT
Force 18 kN
G’s 5g
Max. Stress 289.77 MPa
Max. Deformation 7.42 mm
F.O.S. 1.26
Side Impact :
Force 9 kN
G’s 2.5g
Max. Stress 249.37 MPa
Max. Deformation 9 mm
F.O.S. 1.46
Roll Over :
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BAJA2014_TeamAbhedya_MMCOE_Pune

5. TRANSMISSION SYSTEM
Gear Actual Calculated
1st 31.47 32.55
2nd 18.70 -
3rd 11.41 -
4th 7.63 7.56
Reverse
Gear
55.08 -
Gear Ratios :
Maximum
Speed
59.59 Km/hr
(16.55 mps)
Maximum
Acceleration
2.03 m/s²
Wheel Torque 498.87 Nm
% Gradeability 53.45%
Traction 1571.27 N
Calculations :
• Engine Specifications : Briggs and Stratton (10 HP, OHV, 305cc)
Gear Box Selected :
Make Piaggio Ape
Type Constant Mesh
Shifting Sequential
5- Speed Gear Box
4 Forward &
1 Reverse
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BAJA2014_TeamAbhedya_MMCOE_Pune
ADAPTER

6. STEERING SYSTEM
Camber (Static) -1° (Front)
+1° (Rear)
Caster 5°
Steering Axis
Inclination
8°
Scrub Radius 96 mm
Toe in 3 mm
• Steering Selection : Front Wheel Steering
• Steering Gear Mechanism: Ackermann Mechanism
• Steering Gear Type: Rack and Pinion
Specifications :
Configuration :
Steering Effort
(Static)
40.01 N
Lock to Lock Turns 3.2
Turning Radius 3.72 m
Steering Ratio 15:1
Calculations :
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BAJA2014_TeamAbhedya_MMCOE_Pune

7. Front
Double Wishbone (Short-Long Arm and
Parallel) with Coil Spring and Damper
Rear McPherson Strut
a. Maintain undamped natural frequency from 1 Hz-3 Hz.
b. To keep rear suspension 30% stiffer than the front.
c. Minimize chassis roll by maintaining roll gradient in a range of
1-1.8°/g (of acceleration)
SUSPENSION SYSTEM
Suspension System Employed :
Design Target :
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BAJA2014_TeamAbhedya_MMCOE_Pune
FEA Report of Wishbone :
Force 4687 N
Max. Stress 138.05 MPa
Max. Deformation 0.40 mm
F.O.S. 2.64
Sprung 300 kg.
Unsprung 80 kg.
Max. Mass:

8. Parameter Front Rear
Load on Each Spring (P) (Considering 2g) 1177.20 N 1765.80 N
Spring Index (C) 9 10
Mean Coil Diameter (D) 81 mm 90 mm
Wire Diameter (d) 9 mm 9 mm
Active Turns (N) 10 6
Free Length (L) 212.33 mm 194.73 mm
Deflection (δ) 93.33 mm 115.73 mm
Spring Stiffness (K) 12.61 N/mm 15.25 N/mm
Torsional Shear Stress (τ) 387.03 N/mm² 635.07 N/mm²
Permissible Shear Stress (τ) 650 N/mm² 650 N/mm²
SPRING DESIGN
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BAJA2014_TeamAbhedya_MMCOE_Pune
Parameter Front Rear
Wheel Rate (Kw) 13.92 N/mm 20.55 N/mm
Roll Stiffness (Kø) 470.71 Nm/ °roll 474 Nm/ °roll
Roll Gradient 1.16 °/g ( where g is lateral acceleration)
Suspension Geometry In Roll :

9. BRAKING SYSTEM
Deceleration 5.21m/s²
Pedal Force 50 N
Stopping Distance 15 m
Total Braking Torque
Required
773.96 Nm
Torque Achieved 1105 Nm
Diagonal Split Braking Circuit
TMC with 19 mm Diameter
All Four Disc Brakes with Effective Radius
102 mm
Double Pot Caliper with 20 mm Diameter
Dimension of Front Tyre : 23x7-10 inch
Dimension of Rear Tyre : 25x8-12 inch
Velocity (v) 12.5 m/s
Weight of the
Vehicle (m)
380-400 kg
Coefficient of
Friction (µ)
0.65
Disc Diameter (D) 0.23 m
Pressure Applied on
Disc (P)
15.53 bar
Area of Piston (A)
6.28 x10-4
m²
Friction Radius (Rf) 0.102 m
Calculations :
Specifications : Parameters & Assumptions :
Brake Layout Circuit :
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BAJA2014_TeamAbhedya_MMCOE_Pune

10. THERMOELECTRIC GENERATOR
Objective Waste Heat Recovery
Working Principle Seebeck Effect
Advantages
1. Weight Reduction upto
13 kg.
2. Battery Charging
Specifications :
Mechanical Electrical
Dimensions 3x3x0.5 in3 Power Output 15W x 4= 60W
Weight 15g x 4 = 60g Voltage 12 V
Material Lead Telluride Current 5 A
Environmental
Maximum Hot Side
Temperature
325 ̊C
Maximum Cold Side
Temperature
30 ̊C
Temperature Difference
260 -295 ̊ C (for Max.
Power Output)
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BAJA2014_TeamAbhedya_MMCOE_Pune

11. 10
BAJA2014_TeamAbhedya_MMCOE_Pune
AN INNOVATIVE STEP TOWARDS SAFETY
Product BETA FOAM 87100-
87124 (Rigid
Polyurethane Foam)
Application Increase Stiffness and
Crashworthiness of
Automotive Bodies.
Tube Without Foam : Tube With Foam :
Peak Load : 32869.2 N Peak Load : 38710 N

12. Department Material Test
Load
(N)
Max.
Equivalent
Stress
(MPa)
Remarks
Calculated Applied
Roll Cage
AISI
1018
( Syt =
365
MPa)
Front
Impact
34353.86 35000 233.17 Safe
Side
Impact
17176.93 18000 289.77 Safe
Roll
Over
8588.46 9000 249.37 Safe
Department Component
Braking Torque (Nm)
Remark
Required A
Braking
Calipers and Disc
Assembly
773.96 1105 Safe
Department Components Parameters Remark
Transmission
Piaggio Ape
Gear-box &
Drive Shaft
Gear Ratio
Drive Shaft
(mm)
Safe
Calculation Actual Calculation Actual
32.55 31.46
13-15 20mm
7.56 7.63
DESIGN VALIDATION PLAN
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13. DESIGN FAILURE MODE EFFECT ANALYSIS
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COMPONENT FAILURE MODE
FAILURE
EFFECTS
S O D
R
P
N
ANALYSIS AND REMEDIES
Drive Shaft Due to Torsional
Shear
Seizure of Vehicle
7 2 3 42
Use Drive Shaft of Gear Box Having
Diameter Equal or Greater than Required /
Calculated.
Due to Extreme
Angular
Displacement
Risk of Accident
at High Speed 7 4 3 84
Use a Suspension System at Rear which
Provides Limited Vertical Wheel
Movement.
Tie Rod Due to Impact Crushing
7 3 2 42
Install Bumper at Vehicle Front.
Lack of Lubrication Improper Handling Proper Lubrication.
Wishbone Arms In Bending Vehicle Seizure
Severe crash 9 5 2 90
Use Material of Higher Bending Strength
and Stiffness. Also Design Arms
Considering Worst Case Scenario.
Brake Tandem
Master Cylinder
Leakage from TMC
Possible
collision
8 2 3 48
Use of 2 TMC of Diagonal Split System.
Brake fluid lines Mechanical Damage
due to Improper
Installation 6 4 2 48
Install Brake Fluid Lines along the Roll
Cage with Snaps.
Roll Cage Welding Failure Complete Seizure
of Vehicle and
Subsystems
6 5 2 60
Maintain Good Weld Quality .
Design Roll Cage Structure for Higher
Dynamic Loads.
Front And Rear
Knuckles
In Extreme Bumps,
Droops and Free Fall.
Breakdown and
Crash.
7 5 2 70
Use Standard OEM Knuckles to Avoid
Damage.

14. PROCESS PLAN
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BAJA2014_TeamAbhedya_MMCOE_Pune

15. COMPONENT COST (₹)
Roll Cage Pipes and
Related Equipment
18,545
Tyres 41,768
Steering 11,600
Suspension System 8,400
Transmission 33,070
Braking System 36,280
Electrical, Battery And
TEG
28,732
Safety Equipment 46,622
Painting 3,000
Other 20,000
Total Cost of Materials 2,48,017
Total Estimated Cost of the ATV = Material Cost +Engine Cost +Labour Cost +Transportation Cost
= 2,48,017+35,000+15,000 + 60,000
= ₹ 3,58,017/-
COST REPORT AND WORKSHOP FACILITIES
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BAJA2014_TeamAbhedya_MMCOE_Pune
Metal Inert Gas Welding
Bending Machine
Geared Head Lathe Machine
Universal Radial Drilling Machine
Universal Gear Head Milling Machine
Chop Saw, Power Hack saw
Electric Arc Welding Machine
Spot Welding Machine
Bench Grinder, Hand Grinder
WORKSHOP FACILITIES :

16. BAJA2014_TeamAbhedya_MMCOE_Pune
THANK YOU…
OUR SPONSOR:
MARATHWADA MITRA MANDAL’S COLLEGE OF
ENGINEERING, KARVENAGAR, PUNE
Amount ₹ 1,75,000/-