A

Project report

on

DESIGN AND MANUFACTURING OF ALL-TERRAIN VEHICLE

Summited For

Completion of Degree B. Tech Mechanical

Submitted by

KARTIK BHARDWAJ 16162039

HARISH JANGRA 16162043
HARSHIT THAKRAL 16162005
MANSI DESWAL 16162003
DEEPANSHU 16162028
PALLOVE KAUSHIK 16162050
AASHISH 16162026
th
B.Tech. (Mechanical Engineering, 4 Year, GJUS&T, Hisar)

Under the Supervision of

RAJENDER SIR
Assistant Professor
(Department of Mechanical Engineering)
(Guru Jambheshwar University of Science &Technology, Hisar)

2016-2020

DEPARTMENT OF MECHANICAL ENGINEERING

GURU JAMBHESHWAR UNIVERSITY OF SCIENCE AND TECHNOLOGY

HISAR, 125001
 CONTENT
1. Introduction

2. Objective

3. Scope of project

4. Different views of ATV

5. Parts Nomenclature

6. Tools and technology incorporated

7. Time scale of project

8. Cost incorporated

9. Key features of project

10. Challenges faced in project

11. Conclusion

12. References
 1.INTRODUCTION

In the constantly evolving field of automotive engineering, researchers and designers

continuously look to accomplish two tasks. They work to not only improve upon designs,
but to also teach and inspire the next generation of engineers to take an interest in the
challenges and rewards of automotive engineering. SAE International hosts a large
number of different collegiate events with two of the most popular being the Formula
SAE and Baja SAE competitions. Both competitions engage students in real-world
engineering design projects. The objective of the Baja SAE competition is to design an
off-road vehicle capable of enduring the rough terrain.
ATVs are four-wheeled motorized vehicles with an overall width or less designed to
operate exclusively on off-road terrain, primarily for a single rider. They're powered by
engines and equipped with four low-pressure tires, wheel for steering, and a seat that is
straddled by the rider.
Automotive vehicles in general and Baja vehicles more specifically, utilize many onboard
systems that allow the vehicle to operate fully. These systems include the steering,
suspension, brakes, engine, drivetrain, and frame. Vehicles also may utilize a variety of
sensors in order to gather data about the vehicle and environment during use. For the
purpose of this Baja vehicle, no sensors will be used in order to reduce complexity, the
potential for failure of components, and vehicle weight.

1.1. Steering System

A vehicle’s steering system comprises of several parts working together to create an
optimal path for the tires to follow. This takes into account factors such as the angle at
which the tires are contacting the surface of the ground and at what angle a tire’s turning
is being controlled from. Starting from the farthest point from the chassis, a vehicle’s
turning is dependent on the camber, castor, and kingpin inclination angle of the tires.

1.2. Suspension
The suspension of a vehicle is critical to both safety and performance. The first and
foremost duty of the suspension is to dampen and absorb the vertical forces that a vehicle
might experience during use. This can include a small shift in weight when the vehicle is
loaded with people or items to a large shift if the vehicle’s tires run into a large obstacle
on the ground. By dampening the vertical forces in these situations, the suspension
protects both the vehicle and passengers from unwanted and potentially harmful vertical
forces. Suspensions also perform two other basic functions. The first is known as ride
height and the second is handling. The ride height of a vehicle refers to the quantity of
vertical forces that a suspension system will effectively be able to negate as well as how
comfortable the ride will be for the driver. The handling refers to how well the vehicle can
be controlled during turning, braking, and accelerating by keeping all four wheels in
contact with the ground.
 1.3. Brakes
Brakes are one of the most important components of a vehicle with regards to accident
avoidance and must function under all possible operating conditions including various
road conditions, wear conditions, weight of the vehicle, and driver experience. Brake
systems must accomplish three primary tasks which are slowing and/or stopping,
maintaining speed on a downgrade, and holding stationary on a downgrade.

1.4. Roll Cage Design

Roll Cage can be called as skeleton of a vehicle, besides its purpose being seating the
driver, providing safety and incorporating other sub-systems of the vehicle, the main
purpose is to form a frame or so-called Chassis. The chassis is the component in charge of
supporting all other vehicle’s subsystems with the plus of taking care of the driver safety
at all time. The chassis design needs to be prepared for impacts created in any certain
crash or rollover. It must be strong and durable taking always in account the weight
distribution for a better performance

1.5 Transmission/ Powertrain

It is the powerhouse of a vehicle. It includes, power generator (engine) and a power

transmission assembly that includes clutch, gearbox & gear train assembly, differential,
power transmission shafts and CV joints. Main purpose of the transmission department is
to choose engine that produce enough power to take out the vehicle form rough off-road
conditions, choosing right set of transmission parts that mate with each other with
minimum possible vibrations and are capable of transmitting the power to the wheels with
required factor of safety. Also, all the parts should be capable of working under tough off-
road environment like high temp, mud, dust, water, and impact. Choosing the right tyre
size to make a balance between off road manoeuvrability and engine power output is also
decided by this department.
 2.OBJECTIVE

The design process of this single-person vehicle is iterative and based on several
engineering and reverse engineering processes. Following are the major points which
were considered for designing the off-road vehicle:

1. Endurance

2. Safety and Ergonomics

3. Cost of the components

4. Manoeuvrability

5. Safe engineering practices.

Design intent has been oriented towards large factors of safety and well-understood
systems. With regard to the competition, completion of the endurance challenge has been
given priority over performance in minor events. Effort has been directed away from
specialty challenges like rock crawl and acceleration in favour of a vehicle fully capable
of completing four hours on the track. This motivation implies diminished efforts towards
weight reduction and vehicle performance, however overall quality and durability have
benefitted.
 3.SCOPE OF PROJECT

Off-road vehicle (ORV), is a vehicle capable of driving on and off paved or gravel
surface. Among ORV types, all-terrain vehicles (ATV) allow only single rider feature,
while utility task vehicles (UTV) allows more than a single rider, and they have been
considered in the scope of the market. The off-road vehicle market has been segmented by
vehicle type, application type, and geography.

Off-road vehicles have been gaining demand across different application sectors, such as
sports, agriculture, military, tourism, entertainment, and hunting activities. However, the
demand for off-road vehicles for agricultural and military operations has been
significantly increased with the advancement in the vehicle capabilities, offered by the
manufacturers in the market. This project target the audience who wish to drive solely and
oftenly switch between off road and on road
 4.DIFFERENT VIEWS OF ATV

FRONT VIEW

SIDE VIEW

BIRD EYE VIEW

 5.PARTS NOMENCLATURE
Project/ vehicle is divided
into 5 main categories or
groups which are Roll Cage,
Power Transmission,
Suspension System,
Steering System and
braking System. Each of
this group included
hundreds and thousands of
small and large parts.
For power transmission,
main
sub-
parts

includes engine which

generates power, flywheel
which is a mechanical
power storing device and
gives continuous smooth
power output, clutch is mounted on flywheel which is used to
engage or disengage the engine from the wheels/gearbox, gearbox
is mounted on the clutch, differential is mounted after gearbox and
it allows different wheels to spin at different speeds, transmission
shafts and CV joints further transmits power from differential to
the wheels.
Roll cage is the main skeleton of the vehicle. Its cage like
structure protects the driver form the externals direct
impacts and in rollover conditions. It is important not
only for driver’s safety but also for holding different parts together. It provides a rigid
support to all the parts which is necessary for a vehicle’s stability and handling.
Suspension System used for this vehicle is Double Wishbone Type which are named as
upper wishbone and lower wishbone. Struct/damper is coil-over type which is used for
absorbing shocks and maintaining continuous contact of
wheel with ground for better traction.
Steering mechanism used for this vehicle is Ackermann
type and the steering system is fully
mechanical rack and pinion type. Plates are
welded on the hub to limit the turning.
Brakes are hydraulic drum type which were factory fitted inside the hub. Dot 4 type brake fluid is
used. Brakes are only working on the front Wheels. Cylinders of rear drum brakes are jammed
due to rusting.
 6.TOOLS AND TECHNOLOGIES INCORPORATED
 Tools
Power Hacksaw Used for segmenting the pipes to
appropriate lengths.
Drilling Machine Used for making the holes for screws,
bolts.
MIG/TIG/Arc Welding Used for making permanent joints within
the different segments of the pipes and the
sections of the chassis.
Hand Grinder/Cutter Used for grinding of the sharp edges and
also for giving of the smooth finish to
welded joints.

 Technologies/Software
AutoCAD/Fusion 360/Solid works Used for making 2D/3D models of the roll
cage and also for the static and dynamics
analysis.
Lotus Used in analyzing the suspension system of
the ATV both in statics as well as in
dynamics state.
 7.TIMESCALE OF PROJECT

Duration Work Done

(0-2) weeks Initializing of the purchase orders
with complete details of vendor and
the procedure followed.
(2-5) weeks Finalizing of all the purchasing
process and completing the
purchasing process.
(5-15) weeks Completing of all the manufacturing
process.
(15-18) weeks Assembling of the ATV.
(18-22) weeks Testing and modifications.

Complete duration of the project is around (5-6) months.

8.COST INCORPORATED
 9.KEY FEATURES OF PROJECT

The project of BAJA ATV has following significances

1) ATV can ride in off-road with a comfortable and it can he used in anywhere,
where other vehicle is hardly to climb in non-smooth road.
2) The rolling probability is less so that the rider is safe while driving.
3) The frame design is some made that in case of rolling; there will be less chance of
injury of rider.
4) The suspension system are fitted like, it can absorb shock as much as it can which
results the safe driving with no shock to driver.
5) ATV have the power of climbing as well as speed to run in the off-road in any
condition with high turning quality in minimum space
6) High torque engine with 10 horse power
7) ATV have high factor of safety that is 1.5
8) All the tyres are Tube less
9) We use double wishbone A arm suspension system which work best in Off
Roading
10) For the safety of driver we use collapsible steering system.
11) We didn't use any electronic part like battery and self start which can be damaged
in mud ,so there is no chance of electronic failure
12) Large space for cooling of engine
13) Good steering ratio
14) Our ATV have 4 forward and 4 reverse which are very useful in off-road very
less atv have this
15) Fire wall ensure fire protection.
 10.CHALLENGES FACED IN PROJECT

 Sizing and selection of components: Our major challenge was to

select proper components which can work properly (as most of the component
are from scrap) and could meet our design requirements.

 Selecting material for roll cage: A strong and reliable material should
be selected to withstand the load of the vehicle components.

 ATV model and analysis: Modelling and analysis of vehicle is among the most
important task as it helps us determining the exact prototype and helps us in
analysing all the forces acting on the vehicle.

 Welding: It is the foremost challenge for the welder to weld the rollcage and
components on it strongly as a good weld is assign of good vehicle.

 Suspension system and rear tyre alignment: The suspension system connected to
rear tyres creates a challenging situation for us to align the rear tyres

 Brake and steering calculation: Finally, we wanted to create a

calculator to provide us the brake and steering performance calculations which
could calculate the stopping time, Ackerman percentage, required turning
radius, etc.

A picture of Current ATV

 11.CONCLUSION

Baja SAE is an intercollegiate ATV competition run by the Society of Automotive

Engineers. Teams of students from universities all over the world design and build small
off-road cars. All cars have engines of the same specifications main constraints are on
design of ATV and various other parameters like max speed, acceleration achieved,
braking distance etc. With passing years these kinds of competitions are turning head of
many colleges as the importance of projects is one of unavoidable fact.

We believe that we have done our best keeping in regard that it is our first time of being
on such a big platform and also achieved respectable position in the virtual round of SAE
baja 2019.We also believe that this project lay down foundation of future progress also
which can be carry forward by our juniors on this vehicle. This project has made
significant improvement in the work of an automobile and its completion uplifted the
level of final year project and we are proud to be part of it.

We are beholden of all the faculty members who helped us in achieving this goal
 12.REFERENCES

1. 2010 Baja SAE Rules, SAE India.

2. www.wikipedia.com
3. www.howstuffworks.com
4. An Introduction to Modern Vehicle Design: Edited by Julian Happian-Smith