GOVERNMENT POLYTECHNIC COLLEGE

TUTICORIN-628008

PROJECT REPORT
ON

DESIGN AND FABRICATION OF CONVERTIBLE FOUR

WHEEL STEERING VEHICLE

Under the Guidance of

(Thiru. B.RAMESHKUMAR, B.E., M.BA,)

Submitted by
SI NO REG.NO NAME
1 15200561 M.KUMARESAN
2 15200563 A.MAGESHWARAN
3 15200564 M.MAHESH KUMAR
4 15200565 V.MAHESWARAN
5 15200566 P.MANIKANDAN

Submitted in partial fulfillment for the award of

Diploma in Mechanical Engineering of
State Board of Technical Education, Tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC YEAR 2016-2017
GOVERNMENT POLYTECHNIC COLLEGE
 THOOTHUKUDI -628 008

BONAFIDE CERTIFICATE

This is to certify that the project entitled

DESIGN AND FABRICATION OF CONVERTIBLE FOUR WHEEL
STEERING VEHICLE is a Bonafide record work submitted by
selvan.________________________________________

RegNo. ________________________ in the sixth semester Diploma in

MECHANICAL ENGINEERING course during the year 2016 2017.

Guide Head of the Department

Thiru.B.RAMESH KUMAR, B.E, MBA Thiru.P.Muthurasu, M.E,MIE,Phd

Submitted for Board Practical Examination held on_______ _____________

Internal Examiner External Examiner

 OBJECTIVES
The prolonged convention of covering

the vast syllabus with in the short of time resulted in lack of technical

knowledge and unaware of modern mechanics and versatile applications.

So in order to revise this situation and have to clear knowledge about

modern mechanics and machine tools project work has been undertake.

The project resulted in acquiring well defined knowledge about the

modern machine tools and equipments, Mechanism and their versatility.

The Project work includes the Physical and mental co-operation of each

individual.

It evolves out the concept of group

activity. It further promotes co-operation, co-ordination and ability of

individual.

That is a way applying the above concepts, we

have carry out our project is Design and fabrication of Convertible four

wheel steering vehicle. We ourselves planned organized and executed to

bring our project as successful one.

 ACKNOWLEDGEMENT

We take great pleasure in expressing our heartfelt

thanks to the GOVERNMENT POLYTECHNIC COLLEGE for helping
us to complete our project successfully.

We express our sincere and respected thanks our

beloved principal Thiru.V.Subbaraj ME, B.Tech.Ed is having
permitted to use all the availability facilities in bringing out the
project successful.

We extend our sincere thanks to our Head of the

department of Mechanical Engineering Thiru. P.Muthurasu, ME,
MIE,PhD for his kind support and also providing us with his
unhindered support.

We are greatly indebted thanks and we also

extend deep sense of gratitude to our guide
Thiru.B.Rameshkumar B.E, MBA from the depth of our sole for
her able evidence, valuable suggestions, advises and also who
has been a source of inspiration throughout our project.

We also extend sincere thanks to all the staff of

Mechanical Engineering Department who renders their help
throughout our project.
PREFACE
 We thank our director of technical education who has

introduce the subject the Project work for the final semester in Mechanical

Education Project work is the Way of expression of fresh ideas of the student in the

form of design and Fabrication by utilizing the knowledge acquired by them during

the course of Study and is also benefited for the human society. It has given self-

confidence every individual for starting small scale of our own.

For our turn, be have taken the task of designing preparing details and

Assembly drawing and manufacturing of the Design and fabrication of

Convertible four wheel steering vehicle.

For every each fabrication project work, sequence of operation Involves four

important factors

They are:
1. Design of the project

2. Preparation of details and assembly drawings

3. Collecting necessary materials and proper layout

4. Manufacturing and marketing

 CONTENTS
TABLE OF CONTENTS
CHAPTER NO. CHAPTER

1. ABSTRACT

2. INTRODUCTION

3. LIST OF PARTS

4. PARTS DESCRIPTION

5. PARTS SPECIFICATION

6. DETAILED DRAWING

7. WORKING PRINCIPLE

8. COST ESTIMATION

9. APPLICATIONS

10. ADVANTAGES

11. CONCLUSION

12. PHOTOGRAPHS

13. BIBLIOGRAPHY
 Now a days most of the vehicles use
the two wheel steering mechanism as their main handling system. But the
efficiency of the two wheel steering vehicle is proven to be low compared to the
four wheel steering vehicles. Four wheel steering system can be employed in some
vehicles to improve steering response, increase vehicle stability while moving at
certain speed, or to decrease turning radius at low speed.
Four-wheel steering is a technologically,
tremendous effort on the part of automotive design engineers to provide near-
neutral steering. In situations like low speed cornering, vehicle parking and driving
in city conditions with heavy traffic in tight spaces, high speed lane changing
would be very difficult due to vehicles larger wheelbase and track width which
brings high inertia and traction into consideration. Hence there is a requirement of
a mechanism which result in less turning radius and it can be achieved by
implementing four wheel steering mechanism instead of regular two wheel
steering.
Four-Wheel Steering System is not a new
technology but has it not gained popularity over Two-Wheel Steering System even
though experiments have proved that it has excellent maneuverability, high
stability and it is a solution to over steer/under steer. If Four-Wheel Steering is a
better replacement for age old Two-Wheel Steering.
 INTRODUCTION

This project we have implemented to the

different direction steering system for time reduction of turning
radius. Which is used most of all traffic, parking areas and easy to
turning radius for India road conditions.

Steering is the term applied to the collection of components,

linkages, which will allow for a vessel or vehicle to follow the
desired course. An exception is the case of rail transport by which
rail tracks combined together with railroad switches provide the
steering function.

The most conventional steering arrangement is to turn the

front wheels using a handoperated steering wheel which is
positioned in front of the driver, through the steering column,
which may contain universal joints to allow it to deviate
somewhat from a straight line.

Other arrangements are sometimes found on different types

of vehicles, for example, a tiller or rearwheel steering. Tracked
vehicles such as tanks usually employ differential steering that is,
the tracks are made to move at different speeds or even in
opposite directions to bring about a change of course.
 LIST OF PARTS

The vehicle consists of many parts. They are

1. FREE WHEEL SPROCKET

2. BEARING
3. CHAIN
4. WHEEL
5. STEERING
 PARTS DESCRIPTION
The parts and there construction details are briefly given below
FREE WHEEL SPROCKET
 A freewheel (also known as a block) consists of
either a single sprocket or a set of sprockets mounted on a body which contains an
internal ratcheting mechanism and mounts on a threaded hub. Threaded rear hubs
were available in different thread patterns, The condition of a driven shaft spinning
faster than its driveshaft exists in most bicycles when the rider holds his or her feet
still, no longer pushing the pedals. In a fixed-gear bicycle, without a freewheel, the
rear wheel would drive the pedals around
BEARING

The purpose of a bearing

is to reduce friction, most often on a rotating shaft. It
may be made of many different materials including sintered
bronze, which holds oil to reduce friction, and various metals
which are cast in place to make a soft slippery surface for really
heavy shafts. A bearing can also use balls or rods between two
hardened metal surfaces, the balls or rollers convert what would
be a sliding contact to a rolling point contact.
CHAIN

A bicycle chain is a roller

chain that transfers power from

the pedals to the drive-wheel of a bicycle, thus propelling it. Most bicycle chains
are made from plain carbon or alloy steel, but some are nickel-plated to prevent

rust, or simply for aesthetics.

WHEEL

Tires are designed to

support the weight of the vehicle, absorb road shocks, transmit traction, torque and
braking forces to the road surface and maintain and change the direction of travel.
To fulfill these four basic functions, tires are made of resilient rubber and inflated
with high-pressure air. The inner tube in a tire is used for the maintenance of
proper air pressure, but it alone cannot retain air pressure high enough to support
vehicle load or cannot be durable enough to withstand damage or shocks

STEERING WHEEL
 The automotive steering column is a device intended

primarily for connecting the steering wheel to the steering mechanism or

transferring the driver's input torque from the steering wheel.

STEERING SYSTEM

Steering of a four wheel vehicle is, as far as

possible, arranged so that the front wheels will roll truly without any lateral slip.

The front wheels are supported on front axle so that they can swing to the left or

right for steering. This movement is produced by gearing and linkage between the

steering wheel in front of the driver and the steering knuckle or wheel. The

complete arrangement is called the steering system.

REQUIREMENTS OF STEERING SYSTEM

It should multiply the turning effort applied on the steering wheel by the

driver. It should be to a certain degree irreversible so that the shocks of the

road surface encountered by the wheels are not transmitted to the drivers

hand.
 The mechanism should have self rightening effect so that when the driver

release the steering wheel after negotiating the turn , the wheel should try to

achieve straight ahead position

To control the angular motion the wheels and thus the direction of motion of

the vehicle.

To provide directional stability of the vehicle while going straight ahead.

To facilitate straight ahead condition of the vehicle after completing a turn.

The road irregularities must be damped to the maximum possible extent.

This should co-exist with the road feel for the driver so that he can feel the

road condition without experiencing the effects of moving over it.

 PARTS SPECIFICATION

1. FREE WHEEL SPROCKET

No of teeth - 18
Inner Diameter 35mm

2. BEARING
Inner Diameter 25mm
Outer Diameter 52 mm
 Width 15mm

3. CHAIN
Pin pitch 12.7mm
Roller Diameter 7.9MM

4. WHEEL
Diameter 12 CM

5. WHEEL
Diameter 38 CM
Grip Circumference 10 CM
 DRAWING
2D DESIGN VIEW OF OUR PROJECT
WORKING PRINCIPLE
 This is project only made up of easy to

turning and easy to parking system, which is only simply chain drive steering

system and we have connected to the four sprocket attached per separate wheel.

The steering wheel always connecting on small sprocket and other four sprocket

connecting by on steering sprocket. When you need turning put on steering turning

direction and four-wheel drive to chain sprocket instant of four wheel going to

turning steering direction.

This is process controlled fully manually controlled system and simple

making process, which is used sprocket and chain drive system only drive to four

wheel turning are left, right, 900 and 450 turning system.

VEHICLE DYNAMICS AND STEERING

Understeer:

Understeer is so called because when the slip angle of front wheels is greater than
slip angle of rear wheels.

Oversteer:

Over steer is defined when the slip angle of front wheels lesser than the slip angle
of rear wheels.

Neutral steer or counter steering:

Counter-steering can defined as when the slip angle of front wheels is equal to slip
angle of rear wheels
STEERING PRINCIPLES AND COMPONENTS

ACKERMAN STEERING MECHANISM

 With perfect Ackermann, at any angle of steering, the centre point

of all of the circles traced by all wheels will lie at a common point. But this may be

difficult to arrange in practice with simple linkages. Hence, modern cars do not use

pure Ackermann steering, partly because it ignores important dynamic and

compliant effects, but the principle is sound for low speed manoeuvres.

FUNCTIONS OF THE STEERING SYSTEM

To control the angular motion the wheels and thus the direction of motion of

the vehicle.

To provide directional stability of the vehicle while going straight ahead.

To facilitate straight ahead condition of the vehicle after completing a turn.

The road irregularities must be damped to the maximum possible extent.

This should co-exist with the road feel for the driver so that he can feel the

road condition without experiencing the effects of moving over it.

To minimize tyre wear and increase the life of the tyres.

BENEFITS OF THE 4WS MODEL

In conjunction with rear steer mode, four-wheel steering can significantly

improve the vehicle handling at both high and low speeds.
 Due to the better handling and easier steering capability, driver fatigue can
be reduced even over long drives.

Stability of the vehicle increases.

Turning radius of the vehicle can be decreased to a greater extent by rear

steer mode.

TURNING CIRCLES

The turning circle of a car is the diameter of the circle

described by the outside wheels when turning on full lock. There is no hard
and fast formula to calculate the turning circle but you can get close

KING-PIN INCLINATION

The angle between the vertical line and centre of the king pin or steering
axle, when viewed from the front of the vehicle is known as king pin
inclination or steering axle inclination.

CASTOR

In addition to being tilted inward toward the centre of

the vehicle, the kingpin axis may also be tilted forward or backward from
the vertical line. This tilt is known as caster. Thus the angle between the
 vertical line and the kingpin centre line in the plane of the wheel (when
viewed from the side) is called caster angle.

CAMBER

The angle between the centre line of the tyre and the vertical line when
viewed from the front of the vehicle is known as camber.

Positive camber: When upper part of wheel is outside.

Negative camber: When upper part of wheel is inside (towards the center line of
the car)

TOE-IN & TOE-OUT

 The front wheels are usually turned in slightly in front so that

the distance between the front ends (a) is slightly less than the distance between the

back ends (b), when viewed from the top. The difference between these distances

is called toe in. Toe-out is the difference in angles between the two front wheels

and the car frame during turns. The toe-out is secured by providing the proper

relationship between the steering knuckle arms, tie rods and pitman arm.
BILL OF MATERIALS
Sl.No COMPONENTS MATERIAL QUANTITY

1 Free Wheel Sprocket Cast Iron 5

2 Bearing Steel 5

3 Chain Steel 1

4 Wheel Mild Steel 4

5 Steering Wheel Mild Steel 1

 COST ANALYSIS

MATERIAL COST
SL. NO MATERIAL QUANTITY COST

1 SPROCKET 05 1000

2 BEARING 05 1000

3 CHAIN 01 250

4 WHEEL 05 400

5 STEERING WHEEL 01 450

6 PEDAL 01 150

7 CHASIS FRAME 01 350

8 BOLT&NUT 04 100

TOTAL 3700

Material Cost = 3700

Overhead cost = 500

Prime Cost = (Material cost + Overhead cost)

= 3700 + 500 = Rs. 4200 /-

Labor Cost = Rs. 750/-

Total Cost = Prime Cost + Labor Cost

= 4200 + 750

= 4950/-
 APPLICATIONS

It is used in Four wheel Automotive vehicle

 Mainly used for fork lifts
Agricultural and construction machinery
ADVANTAGES
 The vehicles cornering behavior becomes more stable and controllable at

high speeds as well as on wet or slippery road surfaces.

The vehicles response to steering input becomes quicker and more precise

throughout the vehicles entire speed range.

The vehicles straight-line stability at high speeds is improved.

To successfully park the vehicle without any damage.

Reduction of in turning radius.
Easy to steering.
 CONCLUSION

An innovative feature of this steering linkage

design and its ability to drive all four (or two) wheels using a single steering

actuator. Its successful implementation will allow for the development of a four-
wheel, steered power base with maximum maneuverability, uncompromised static

stability, front- and rear-wheel tracking, and optimum obstacle climbing capability.

We can say our project can be a success considering the

changes we had to make in the spring once we actually found out

The project work facilities the students in

knowing the difficulties in the practical field and also it shows the way of solving

these difficulties it also gives us a confidence for standing on our own legs by

employment after finishing studies. This idea in view we have completed the

project with the existing facility the project with the existing facility. Through it

offered to be difficult and in its initial stage. We could overcome all the difficulties.
 BIBLIOGRAPHY

TEXT BOOK:
 A text book of Manufacturing Technology , author
R.K.Rajput

Dr. Kirpal Singh Automobile Engineering Standard

Publishers Distributors, vol. 1, 12th Edition, 2011.

V. B. Bhandari Design of Machine Elements McGraw Hill

Education India Pvt. Ltd., vol. 3, 11th Edition, 2013.

PSG College of Technology Design Data Book Kalaikathir

Achchagam, 2013.

WEBSITE:

http://www.google.com
http://www.wikipedia.com
Four wheel steering report,
http://www.scribd.com/doc/34677964/Four-Wheel-Steering-
report,
Honda official website http://automobiles.honda.com/civic-
sedan/specifications.aspx