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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
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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
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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
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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
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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
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ERGONOMICS 7
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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
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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
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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
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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)
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STEERING SYSTEM
COMPONENTS
1) Steering arms
2) Tie rods
3) Track rod
4) Rack and pinion
5) Steering wheel
12
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)
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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.
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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%
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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
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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
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COST & WEIGHT REPORT 17 Team Effort’s Cost Report
OUR SPONSORS
Total Weight: 300 Kg Total Cost of ATV: Rs. 2,32,000
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MS PROJECT PLAN 18
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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
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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
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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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