1

RULEBOOK ABSTRACT 2

Parameters Rulebook Value Our Value

Length of ATV 108 inch 74.53 inch

Width of ATV 64 inch 59 inch

Helmet Clearance 6 inch 6.3 inch

Material of Rollcage Material with 0.18 % C

content

ASTM-106 Grade-B with

0.19% C content

Wheels Alignment 4 wheels must not be in same line

Shoulder Clearance 3 inch 4 inch

Rear Roll Hoop Inclination Max. 20o 15o

Distance of LDB members

from weld joints Max. 5 inch 2 inch

Angle between FBM to

vertical line Max 45o 43.17o

Brakes The braking system must be segregated into atleast

two independent hydraulic circuit

Car weight

300

Kg

Max. speed

58.38 Km/hr

Ground clearance

330

mm

Turning radius

3.30

m

Max. acceleration

6.13

m/s2

Stopping distance

8.29

m

Stopping time

2.64

sec

TECHNICAL SPECIFICATIONS 3

Design Targets

Roll cage

Brakes

• Brake circuit :Diagonal

• Brake Diameter: 200 mm(F&R)

• Stopping Distance(58 Km/hr.): 13m

• Stopping time(58 Km/hr.): 1.60 sec

Steering System

• Type: Rack & Pinion

• Steering Ratio: 16:1

• Wheel Base: 1600 mm

Suspension

• Type: Double wishbone

• Spring: Concentric Springs

• Deflection: 136 mm

Power train

• Height : 1250.0 mm

• Length : 1893.3 mm

• Width : 850.0 mm

• Ground Clearance: 330 mm

• Wheel Base: 1600 mm

• Track width (mm) : 1500(R) & 1400(F)

• Transmission System: Manual OEM

• Maximum Speed: 58.38 Km/hr.

• Maximum Acceleration: 6.13 m/s2

• Stiffness (N/mm) : 11.15(F) & 18.59(R)

• Free length (mm) : 285(F) & 334(R)

• Damping Ratio: 0.83(F) & 0.76 (R)

• Deceleration :10.11 m/s2

• Pedal ratio: 6:1

• Pedal force: 120N

• Brake Force: 3221.72 N

• Caster Angle: +8o(F)

• Camber Angle: -2o(F)

• Toe Angle: 0o(F)

• Gradeability : 46.99%

• Tractive force: 1963.15 N

2D/3D VIEWS OF THE ATV & ITS PARTS 4

Roll Cage A-Arms &

Knuckles

Springs Final ATV

FINAL DESIGN

FIRST DESIGN

FRONT

SIDE

TOP

FRONT

REAR

CONCENTRIC

SPRINGS

ROLL CAGE ANALYSIS 5

Frontal Impact

1) Load: 4g

2) Stress: 70 MPa

3) Deformation: 1.01 mm

4) F.O.S: 3.43

Rear Impact

1) Load: 4g

2) Stress: 80 MPa

3) Deformation: 2.14 mm

4) F.O.S: 3.0

Side Impact

1) Load: 1g

2) Stress: 110 MPa

3) Deformation: 2.86 mm

4) F.O.S: 2.20

6

Torsion

1) Load: 1g

2) Stress: 76 MPa

3) Deformation: 0.76 mm

4) F.O.S: 3.15

Roll Over

1) Load: 1g

2) Stress: 52 MPa

3) Deformation: 0.30 mm

4) F.O.S: 4.63

Modal

1) Frequency: 41.97 Hz

2) Deformation: 14.1 mm

Bump

1) Load: 1g

2) Stress: 170 MPa

3) Deformation: 5.33 mm

4) F.O.S: 1.4

ERGONOMICS 7

SUSPENSION 8

PARAMETER FRONT REAR

Type of suspension Double Wishbone

with unequal lengths

Double Wishbone

with unequal lengths

Ground clearance 330 mm 300 mm

Tyre size 635 mm outer dia. 635 mm outer dia.

Max vertical wheel

travel

177 mm up & 127

mm down

127 mm up & 100

mm down

Suspension ratio 0.46:1 0.61:1

Anti-dive 13.43% -

Anti-squat - 13.09%

Camber -2 -2

Caster 8 NA

Kingpin Inclination 12o NA

Mech. Trail or

Caster Trail 44.62 mm NA

Scrub Radius 24.09 mm NA

REAR

FRONT

Minimum F.O.S: 4.4

9 FRONT REAR

SUSPENSION(LAYOUT)

Consideration Priority Reasons

FRONT SUSPENSION

Simplicity Essential This is a main goal of the team overall

Light weight Essential Weight is the number one enemy of a race car, especially sprung weight

304 mm of Travel High Turning and stopping both require contact between the tyre and the ground, which

is achieved through travel

Durability High Withstand abusive-driving during the endurance race

Shock Absorbing Desired Frontal impact cause a heavy amount of damage to the car

Compatible with Steering

REAR SUSPENSION

Simplicity Essential Easier to fix, build, design, analyze

Lightweight Essential Less weight is essential to be competitive

227 mm Travel High Allows tyre to be on the ground situations and still have traction

Durability

High Withstand abusive-driving during the endurance race

CONCENTRIC SPRING 10 Parameters Front Rear

Inner Outer Inner Outer

Wire diameter (mm) 6 8 6 9

Coil diameter (mm) 54 72 54 81

Active coils 22 14 29 17

Total coils 24 16 31 19

Load (N) 571.92 945.39 953.31 1575.82

Stiffness(N/mm) 4.20 6.95 11.58 7.01

Clearance between springs

(mm) 3 6

Deflection of spring (mm) 136 136

Critical damping

value(body) (Ns/m) 1776.17 2778.84

Critical damping

value(wheels) (Ns/m) 2412.75 2492.78

Wheel rate (N/mm) 2528.68 7255

Critical damping force (Cr)

(N) 1826.35 3095.81

Damping Ratio 0.83 0.79

Maximum Shear Stress: 457 MPa

Deflection of Spring: 136 mm

STEERING 11

Track width:

1400 mm

Wheelbase 1600 mm

Steering Ratio: 16:1

Scrub radius: 24.09 mm

C-Factor: 33 mm

Mechanical trail: 44.62

mm

Turning Radius: 3.3 m

(outer Front)

Two Wheel Steering

System layout

STEERING SYSTEM : 2 Wheel steering System

(OEM)

STEERING SYSTEM

COMPONENTS

1) Steering arms

2) Tie rods

3) Track rod

4) Rack and pinion

5) Steering wheel

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TRUE ACKERMANN GEOMETRY

Rif =

)tan(

1

)tan(

1

l

e

2sin

ebl

Formulas for 2 wheel steering system:

2sin

ebl

Rof =

2tan

ebl

Rir =

e= Distance between two tie rods ends

l= Wheel base

b= Track width (F) ∅= Inner wheel lock angle

ф= Outer wheel lock angle

Rif= Radius (inner front)

Rof= Radius (outer front)

Rir= Radius (inner rear)

BRAKES 13

Front Axle Load 808.5 N

Rear Axle Load 1347.5 N

Front Axle Load 1537.57 N

Rear Axle Load 618.42 N

STATIC LOAD DISTRIBUTION

DYNAMIC LOAD DISTRIBUTION

During Max .Acceleration 6.13 m/s2

Dynamic Front Axle

Load 366.44 N

Dynamic Rear Axle

Load 1789.55 N

Components

• All 4 Disc combination used to

achieve 4 Wheel Lock.

• Disc Used –200 mm (OEM)

• Master Cylinder Used – (OEM)

Remarks

• This particular combination of

Calipers is chosen due to its Ease of

Mounting Bleeding points on top.

• Diagonal Braking Circuit Split used

so that braking power is available on

both Axles in case one Circuit Fails.

14 BRAKE

CIRCUIT

Type of brake used Disc Brake

Front 200 mm

Rear 200 mm

Master Cylinder 1 tandem master

cylinder

Brake circuit Diagonal type

Brake Force 3221.72 N

Stopping distance

(58 km/hr.) 13 m

Deceleration 10.11 m/s2

Stopping time

(58km/hr.) 1.60 sec.

Pedal force 120 N

Pedal ratio 6:1

• Total weight of vehicle is 300 kgs

• Load on front axle is 37.5%

• Load on rear axle is 62.5%

POWER TRAIN

TYRES

15

Torque (ft-lbs,

gross)

14.50

Engine

Displacement

(cc)

305

Number of

Cylinders

Single

Engine

Configuration

Horizontal

Shaft

Engine

Technology

OHV

Length (in) 12.3

Width (in) 15.4

Height (in) 16.4

Weight (lbs) 50.4

Bore (in) 3.12

Stroke (in) 2.44

Engine Fuel Gasoline

Spark Plug RC12YC

MAX. TORQUE AT

2600 RPM

ENGINE SPECIFICATION

• Duro -Power Grip ATV Tyres

• Dimension : 25x8-12 ;

6 Ply Rating

• This tyre is radial constructed that

designed to help alleviate the hard

impact when riding riding on rough

terrain with pits & gravel & boost

driving comfort.

• Innovative sidewall & ply structure

aids in protecting the tyres from

punctures , protect the rim & boosts

the life of tyre

DESIGN METHODOLOGY OF TRANSMISSION 16

Quantity

Gear

1st

2nd

3rd

4th

Reverse

Gear Ratio 31.48 18.7 11.4 7.35 55.08

Velocity(m/s) 3.8 6.41 10.52 16.31 2.07

Acceleration

(m/s2) 6.13 3.63 2.21 1.42 10.70

Tractive force(N) 1963.15 1163.80 709.12 457.10 3425.51

Gear Box :

4 Forward and 1 Reverse

(OEM)

Transmission System: 2 Wheel Rear Drive ATV

COST & WEIGHT REPORT 17 Team Effort’s Cost Report

OUR SPONSORS

Total Weight: 300 Kg Total Cost of ATV: Rs. 2,32,000

MS PROJECT PLAN 18

Design

Parameter

Potential failure

mode(s)

Potential

cause(s) of

failure

Potential effect(s)

of failure S O D RPN Preventive actions

Roll Cage Bending and

buckling Impact load High risk to driver 9 1 5 45 High factor of safety

Axle shaft Bending and fracture

Impact load

and excess

wheel travel

Failure of Power

train 6 2 3 36

Provide sufficient deflection

and damping to suspensions

A-arms

Spring

Knuckle

Bending

Static and

Dynamic load

Failure of

Suspension and

Steering System

5 1 4 20 High factor of safety

Torsional Shear

and/or Buckling 6 2 4 48 Use Concentric Springs

7 1 6 42 High Factor of Safety Direct Shear and

Bending

Tie rod

Bending of rod

and/or fracture of

ball-joint

Front impact

and excess

wheel travel

Failure of Steering

System 5 2 2 20

Provide sufficient deflection

and damping to suspensions

Master

Cylinder

Loss of hydraulic

fluid

Leakage in

hose

Failure of Braking

System 7 2 3 42

Use hose material with higher

strength

Testing part/Equipment Method Theoretical

Value

Actual

Value

Ground clearance Measurement by Steel Ruler 13 inch

Stopping Distance Measurement by Measuring tape 11m

Speed Using Stopwatch 58.8 Km/hr.

Turning Radius Practically (Figure test; Measuring tape) 3.3m

Steering Ratio Protractor 16:1

DFMEA

DATA

VALIDATION

PLAN

19

MANUFACTURING PROCESS 20 Processes which Team is going to use for Fabrication

Cutting Process Hacksaw Machine cutting

Drilling Process Drilling Machine

Turning Process Lathe Machine

Bending Process Bending Press

Welding Process Manual Metal Arc Welding

Grinding Process Grinding Machine

WORKSHOP FACILITIES

Chitralekha N. (Faculty Advisor)

Vyom Makani (Vice Captain)

Power Train

Parth S.

Kevin C.

Suspension

Hanee Patel

Aniket Patel

Nikhil G.

Brakes

Sahil Bali

Samay Patel

Roll Cage

Vyom Makani

Pranav Mehta

Steering System

Nikhil G.

Jay Vyas

TEAM ORGANIZATION 21

Kamlesh S.

(Faculty Advisor)

Samay Patel(Captain)

Roll cage

Pathik Patel

Aditya Dave

Suspension

Ruchik Raval

Hanee Patel

Steering System

Jay

Vyas

Amit

Dev

Brakes

Avnesh Rawat

Bhavik Purohit

Power Train

Milind Kadiya

Jay Joshi

MARKETING Sunny Patel

Utsav Shah

Divyansh U.

Utsav B. Samay Patel

Design Team

Fabrication & Logistics Team

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