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INTRODUCTION
The initiative towards BAJA 2011 was taken
with an aim to have a hands-on experience
in designing an ATV keeping in view the
ease of manufacture and economy. The
design was made by use of the modeling
software CATIA V5 R18, and was analyzed
by FEM analysis software ANSYS 10.0.
The ergonomics and the theme GO GREEN
were the key points in vehicle design.
Acceleration Performance:
Speed (kmph)
Time (sec)
0-10
1.38
0-20
3.88
0-30
7.30
0-40
14.42
0-50
21.89
TECHNICAL SPECIFICATIONS
Engine: Lombardini LGA340
Drive: Rear wheel direct drive
Suspension:
Unequal
double
wishbone independent suspension
Time in seconds
(Kmph)
1st
2nd
3rd
4th
0-10
1.38
10-20
2.50
Steering:
Manual steering with
optional four wheel steering.
20-30
3.42
30-40
7.12
Dimensions:
Max length = 2350mm
Height = 1652mm
Wheel base = 1670mm
Ground clearance = 320mm
40-50
7.47
1|Page
OF
THE
COMPLETE
FRONT VIEW
Design Considerations
Place of seat, steering
All levers, switches should be in reach of
drivers hand
sufficient Leg room, head room
Fire executor will near to the feet. Driver
and external human both should reach.
Weight of roll cage = 72 kg (approx).
Material used
The commonly used materials for
tubing are 1018 Mild Steel. The frame will
be built using MIG welding.
Material Properties:
OD: 26.9mm
ID: 21mm
Density: 7860kg/mm3
C %: 0.18
SIDE VIEW
Analysis
The user friendly ANSYS is used for
the analysis of the roll cage. The conditions
are given below.
FRONT COLLISION ANALYSIS
In this case a deceleration of 10 Gs
is the assumed loading. This is equivalent to
a 33375N load on the vehicle. In image of
the FEA, the scale shows stress distribution.
ISOMETRIC VIEW
RESULTS:
ROLL CAGE DESIGN & DRIVER
ERGONOMICS
Page | 2
Deflection: 2.244mm
RESULTS;
Deflection: 18.114mm
Von misses stress: 369.177 N/mm2
SHOCK
MOUNT
IMPACT
ANALYSIS
In this case, shock mounts caused by
a 5 G load on it. This is equivalent to a
loading force of 3800N on single front
wheel. The resulting stresses from this
loading are seen in Figures.
RESULTS;
Deflection: 11.646mm
Von misses stress: 363.064 N/mm2
ROLLOVER IMPACT ANALYSIS
Page | 3
RESULTS;
Deflection: 5.77mm
Von misses stress: 157.551N/mm2
DRIVER ERGONOMICS
Driver ergonomics is one of most
important thing in ATV vehicle design. The
vehicle is designed with considering the
easy reach to all switches placed in driver
cabin, proper handling grip to steering, the
seating position is maintained to have good
grip to gear lever, hand brake lever. Cabin is
designed to easy entry and exit to vehicle.
ABC pedals are placed ergonomically and
ensured the effort less pedal activation.
Front side is maintained at low position so
that there should not be any blind spot for
driver.
SUSPENSION DESIGN
At 4g load,
R=49.8195/2=1878N
=12.783
=6.469 r=19.415
Q=R1sin(r-)/ (sinrtan+cosr)
=1860.1150N
U=R1/ (sin r tan +cos r) = 1815.2107N
S=U a/b=2517.7969N
Load on spring = F = S/cos = 2788.15N
For 1g load,
Sprung mass=95kg
Q=R1sin(r-)/ (sinrtan+cosr) =
495.8701N
Page | 4
Deflection = 8nFD3/Gd4=137 mm
=k*8*F*D/*d3=541.5 N/mm2
= k*8*F*D/*d3=516.88 N/mm
STEERING DESIGN
Sprung mass=245kg
Max travel of the wheel centre: 150mm
Camber variation:2(at droop) to -4(at
bump)
For 4g load, R=4*9.81*295/2=4794 N
=28.091,
=5.509, r=5.329,
For 1g load,
R=1*9.81*295/2=1199 N
Cot()Cot()=track/base
=3.842,
Cot(25.65)Cot(36.412)=0.7267
=8.491, r=6.007,
C/b=1210/1670=0.7245
P rear=125.49N,Q rear=1208.50N
S rear=1617.89N
Load on spring=F=S/cos=1644N
Therefore, Net load =3841.97N
n=12 C=7.5 d=8mm D=60mm
Spring stiffness (K): 13.77 N/mm
Spring length: 217 mm
No. of springs=4
Deflection=8nFD^3/Gd^4=110mm
Fig: Ackermans principle
Maximum working shear stress
Turning radius=(b/sin )+(a-c)/2
Page | 5
=(1670/sin25.65)+(1350-1210)/2
=3.92meter
Layout:
Calculations:
1200mm 470mm
Fig : Forces involved in Braking
Steering armlength(l)=165mm
CG height: h=564.287mm.
Pinion dia.(d)=3mm
In static condition:
Torque on pinion,(Mtp)=Pxd/2=3606.8Nmm
Lf + Lr = 4022.1 N
Lf 1200=Lr 470
Mech.efficiency of system(m)=0.85
In dynamic condition:
Lf 1200=2847.245564.287+ Lr 470
Lf =2094.043 N, Lr =1928.057 N
Accounting the weight transfer,
For =0.3
and
= 235.3267 Nm
Similarly, Tr =216.662 Nm
Total torque:
T=2 (235.3267 +216.662)
=904 Nm
PART2:
Force that can be applied by right foot for 5 th
percentile female is 445 N.
f=100N;
m/s2
POWERTRAIN DESIGN
Gearbox: 4 speed constant mesh manual,
M&M Alfa champion.
Gear
Gear ratios
kmph per
1000 rpm of
engine
So pressure obtained is
1st
31.48
3.80
P= (1205)/ (0.019052/4)
2nd
18.70
6.40
=2.105106 N/m2
3rd
11.40
10.50
=21.05 bar
4th
7.35
16.28
Reverse
55.08
2.17
Max.
=22.105106 0.0512/40.30.09154
=944.30 Nm
Gear
Max. Speed
in Gear in
Kmpl
Gradability in %
(At Speed in
kmpl)
1st
13.69
43.43 (9.89)
2nd
23.04
22.51 (16.64)
3rd
37.80
11.55 (27.30)
4th
58.63
5.18 (35.83)
In our case,
Page | 7
Shaft angularities:
Suspension Left Axel
positions
Angle
Right Axel
Angle
Top
1.80
2.93
Normal
9.87
15.84
Bottom
13.86
21.80
Engine Mounting:
Engine is mounted on two C section
of 4507030 welded to roll cage. Rubber
pads are inserted between engine bottom and
C section for vibration isolation. Engine,
rubber pads and C section are assembled
through bolting.
Gearbox Mounting:
Gearbox is attached to engine
through bolting at one side. Other side of
gearbox is mounted on elastic support
member
having
lower
vibration
transmissibility. The mounting of elastic
support member has been done using square
sections and pipe section. Elastic support
member is attached to square section
through bolting and square section is
attached to roll cage through welding.
Drive line:
Power from Alpha Gearbox to
Maruti 800 hub is transmitted thorough
propeller shaft. Propeller shaft is made up of
two shafts connected together by Muff
coupling. Driveline layout is shown below
Page | 8
System
No. of Total
parts
cost(Rs)
Engine
12
31030.25
Transmission 16
22989.19
Suspension
23
24999.62
Wheels
7
38881.64
Brake
23
9899.98
Steering
38
12720.87
Body
12
41762.74
Electrical
13
15050.00
GO GREEN COMPLIANCE
INNOVATIONS
Optional four wheel steering:
We have designed optional 4W
steering. The driver can use front wheel or
four wheels steering to turn the vehicle. Use
of four wheel steering gives turning radius
of 2.9m.
4W Steering Effort
Page | 9
ACKNOWLEDGEMENT
We are very thankful to Society of
Automotive Engineers for organizing BAJA
SAEINDIA event. This event is a great
opportunity providing a platform for
students to explore their talent.
We are also thankful to our college
faculties:
Dr. S. P. Chavan (HOD Mechanical Dept.)
Dr. K. H. Inamdar (Senior Faculty Advisor)
Prof. A. U. Paranjpe (Faculty Advisor)
REFERENCES
Fundamental of Vehicle Dynamics By
Thomas Gillespie.
Automobile Mechanics By Dr. N. K. Giri.
Automobile
Singh.
Engineering
By
Kirpal
Page | 10