Car No.

1  Readily availability of material

 Higher Yield strength material

Design Report of All-Terrain  Simple structure for ease in fabrication

Vehicle of BAJA 2018  Aesthetics for an eye catching model.

AISI 4130 ChroMoly steel is the best suitable material as

Team Tachyon 2.0 it has a greater strength to weight ratio. Moreover, the tube
diameter was selected based on values of bending stiffness
Abstract & bending strength

The aim of Baja Collegiate Competition is to design, Dimension of tubes

analyze and fabricate an All-Terrain Vehicle. The objective
of the design and analysis of the ATV is to develop Primary Tubes: 1.15” Outer Diameter 1.65mm wall
compact, safe, light weight, efficient, durable and vehicle thickness
capable of running on different type of terrain.
Secondary Tubes: 1” Outer Diameter 1.6mm wall
Competitiveness of the vehicle in terms of ruggedness and thickness
maneuverability was considered during the preliminary
design of the vehicle. The different component like Verification of primary tube cross section
reduction gear box, knuckle , hub, steering system, and Yield Strength of AISI 4130 ChroMoly (S ) =460MPa
y
suspension system were designed using SOLID WORKS
Modulus of Elasticity (E) =205GPa
and these designed were analyzed in the ANSYS and the Outer diameter of the tube (D ) =29.2mm= 0.0292m
0
suspension system in LOTUS, to find out the stress Inner diameter of the tube (D ) = (29.2-2*1.65) mm
i
concentration, factor of safety and to find out the behavior
=25.9mm=0.0259mm
of the component in different condition. 4 4
Moment of Inertia (I) =π (D - D )/64
0 i
We went for iterative design & analyze to improve and 4 4
= π[(0.0292) -(0.0259) ]/64
ensure the performance of the vehicle without the failure of -8 4

any components during the competition. The vehicle was =1.35976*10 m

fabricated with the collaboration of all the team member
Distance of outer fiber from Neutral Axis (C) = D /2
using the engineering design and meeting the criteria of the 0
=0.0146m
BAJA-2018 rule book.
Bending Strength (M) = [S I]/C
y
Introduction 6 -8
=460*10 *1.335976*10 /0.0146
Vehicle Overview = 428.42N-m

Parameters Value Bending Stiffness = EI

9 -8
Mass 170kg
= 205*10 *1.35976*10
Wheel base 60in. 2
Track width 51in.(Front) = 2787.5N-m
51.5in.(Rear) Hence, the tube cross section dimension is eligible for
Acceleration 5.4m/s2 usage to make roll cage.
Max. Speed 59kmph
Gradeability 123%
Stopping Distance 9.75m Material Selection

Parameter AISI 4130 AISI 1018

Roll Cage Yield strength 460Mpa 370Mpa
Tensile 560Mpa 440Mpa
Roll cage is the component in charge of supporting all other Strength
vehicle’s subsystems and taking care of the driver’s safety Elongation 10% 15%
at all time. The chassis design need to be prepared for Modulus of 205GPa 205GPa
impacts created in any certain crash or rollover. It must be Elasticity
strong and durable taking always in account the weight Density 7.87g/cc
distribution for a better performance. Hardness (HRB) 100 90

Design Consideration Weldability Very Good Excellent

 Driver’s Ergonomics

 Light weight material

 Low cost of material

Design of Roll Cage Impact force calculation model
Mass (m) =265kg

Impact time (dt) = 0.243s

Impact velocity (dv) =16.667 m/s (60kmph)

Impact force (F) = m (dv/dt)

=265*(16.667/0.243) = 18200N =7g

Front Impact
Total Force Applied 18200N(7g)
Max. Deformation 1.206mm
Max. Stress 384.84Mpa
No. of Nodes Selected for Force 4
Factor of Safety 1.12

ROLL CAGE 3D MODEL (SOLIDWORKS)

Rear Impact

Total Force Applied 18200N(7g)

Max. Deformation 1.584mm
Max. Stress 359.35Mpa
No. of Nodes Selected for Force 6
ROLLCAGE (FABRICATED) Factor of Safety 1.28

Roll Cage Specification

Parameter Value
Mass 38kg
Total no. of nodes 58
Total Tubing length 32.14m
Length 73.83in.
Width 33.27in. Side Impact
Height 48.45in.
Total Force Applied 9100N(3.5g)
Max. Deformation 1.716mm

Finite Element Analysis of Roll Cage Max. Stress 158.06Mpa

No. of Nodes Selected for Force 2
Finite element is a method for the approximate solution of Factor of Safety 1.58

partial differential equations that model physical problems

such as: solution of elasticity problems, determine
displacement, stress and strain fields. static , transient
dynamic, steady state dynamic, i.e. subject to sinusoidal
loading, modes and frequencies of vibration, modes and
loads of buckling. Roll cage was analyzed at much higher
forces than in real case scenario.
 Transmission system
In order to design appropriate layout for the
transmission system for our ATV, we need to select a
suitable reduction gearbox and CVT. The selection of a Reduction Gearbox Specification
suitable transmission system is done by comparing the Components Module No. of Width Pressure
values of traction available and required to accelerate the (mm) tooth (mm) angle
vehicles which is calculated from the gear ratio of various Wheel gear 1 2 67 15 200
gear box.
Pinion 1 2 18 20 200
Layout of transmission
Engine> CVT >Reduction Gearbox >Drive Shaft >Rear Wheel gear 2 2 57 15 200
Wheels
Pinion 2 2 18 15 200
Engine Specification:
Name Briggs & Stratton
19L232 0054-G1
Max. Power @3600rpm 10hp
Max. Torque @2600rpm 19Nm
Cylinder Capacity 305cc
Max Speed @ No load 3800rpm
Intake Fuel Petrol
Cooling system Air Cooled
No. of Cylinder Single Cylinder

CVT Specification
Specifications Driver Pulley Driven Pulley Performance Values:
Max Diameter 186mm 198mm Specifications Value

Min Diameter 66mm 80mm Maximum Torque @ wheel 672.6 Nm

Pulleys Centre to 232mm Maximum Speed 59.22 kmph
Centre Distance
Maximum Acceleration 7.66 m/s2
Length of The Belt 915mm
Maximum Gradeability 510 (123%)
Groove Angle of the 320 320
Pulley
Tyre & Rims Specification:
 Tyre : Carlisle AT 489 23x7-10
Gearbox Material:  Front Rim : DWT 10x5 (4+1)
Gears: 20MnCr5  Rear Rim : DWT 10x6 (2+4)
Casing: Aluminium 7075 .

Calculation of Transmission at various engine rpm

Rpm Torque Gear CVT Total Torque Force Acceleration Velocity Gradeability Gradeability
(Engine) ratio ratios Gear (Wheel) (N) m/s2 kmph Ø %
Nm Ratio Nm

2000 18.4 11.8 3 35.40 651.36 2298.89 7.41 6.03172 48.8 114

2200 18.6 11.8 3 35.40 658.44 2323.88 7.50 6.63489 49.5 117

2600 19 11.8 3 35.40 672.60 2373.85 7.66 7.84123 51 123

3000 18.7 11.8 2.02 23.84 445.73 1573.16 4.99 13.437 30.5 59

3400 18 11.8 1.04 12.27 220.90 779.623 2.35 29.5786 13.8 25

3600 17.6 11.8 0.55 6.49 114.22 403.138 1.09 59.2205 6.3 11
Steering System Parameters Front Rear

Primary function of steering system is to achieve Double Semi

Suspension Type
Wishbone Trailing Arm
angular motion of the front wheels to negotiate a turn. This
is done through linkage and steering gear which convert the Roll Centre Height 6.24” 4.13”
rotary motion of the steering wheel into angular motion of
Motion Ratio 0.55 0.78
the front wheels.
Natural Frequency 2Hz 2.4Hz
Steering geometry Ackerman geometry
Spring Rate 12.6N/mm 25.1N/mm
Oversteer or understeer Understeer
Ride Rate 3.81N/mm 15.27N/mm
Ackerman percentage 81%
Bump 4” 3”
Inside lock 43° Travel
Droop 2” 1.5”
Outside lock 27.48°
Damping Coefficient
Turning circle radius 2.27m 1658 2639
(Ns/mm)

Damping Force 2582 N 3632 N

Steering gear : Rack & Pinion
FOX Float 3 FOX Float 3
LHD or RHD CENTRAL DRIVE Shock Absorbers
Evol R Evol R
Rack travel 124 mm

Turns lock to lock 1.89 rev

Braking System
Steering ratio 7:1

IBJ centre distance 152.4mm A braking System is an assembly of several mechanical

devices which inhibits the motion of the vehicle by
OBJ centre distance 476.5mm
decelerating.
Length of tie rod 380mm
Circuit type F/R Split
Steering wheel diameter 250 mm
TVS TMC , Bore 19.05mm,
Steering wheel torque 6.6 N-m Master Cylinder
Stroke 15mm & 14mm

FRONT REAR

Rack & Pinion Specification SS410 170mm OD SS410 235mm OD

Brake Disc
64mm PCD 110mm PCD
Teeth on Rack : 32 4mm thickness 4mm thickness
Teeth on Pinion : 17
Material of Rack : EN8 Brake Callipers KBX
Material of Pinion : EN8 Brake Fluid DOT 4
Material for Casing : Aluminium 7075

PERFORMANCE
Suspension System
Stopping Distance 9.75m
The suspension system is one which separates the
Pedal Force 256N
wheel/axle Assembly from the body. Suspension provides
vertical compliance so the wheels can follow the uneven Pedal Travel 46mm
road, isolating the chassis from roughness in the road. It
REFERENCES
maintains the wheels in the proper steer and camber
attitudes to the road surface.  Gillespie, Thomas; “Fundamentals of Vehicle
Dynamics”
Camber 1.5°(+ve)  Jazar, Reza; ‘Vehicle Dynamics - theory &
Application’
Castor 3°(+ve)
 Smith, Carroll; ‘Tune to win’
Toe 1°(in)  Limpert, Rudolf; ‘Brake Design and Safety’
 Richard Stone and Jeffrey K. Ball; ‘Automotive
Steering Axis Inclination 11.58°
Engineering Fundamentals’
Scrub 0.58”(+ve)  Milliken & Milliken; ‘Race car vehicle dynamics’
 Graphs
ACCELERATION VS
INSIDE VS OUTSIDE VELOCITY
35
ANGLE 6
30
4
25
Outside Angle

2
20
0
0 20 40 60
15

10
25 21.96
5

0
Inside Angle 20
15.22

)
0 20 40 60

Stopping Distance(m
15
TORQUE @ WHEEL VS. 9.75
ENGINE RPM 10
5.48
600 5 2.43
500 0.6
400 0
10 20 30 40 50 60
300
Speed (kmph)
200
100
0
1500 2500 3500 4500
Drawings

*All Dimensions are in Inches

Roll Cage

Front Knuckle
Drawings

Front Hub

Rear Knuckle

Rear Hub
Drawings

A-arm

Semi Trailing Arm