DRIVE AXLE Weight of car + driver = 400 kg.

Assuming the worst case of 100% weight transfer to the rear wheels on launch, a coefficient of friction of 1.3, and a tire with a 266 mm rolling radius, the maximum torque per axle would be, Tmax = (400 x 1.3 x .266)/2 = 58.76 kg-m Using this torque, and the Handbook stress calculation for a solid half shaft, we have: Stress, =16T/d3 Assuming that shear ultimate is 75% of tension ultimate (again from the handbook) the ultimate shear stress would be : x .75 = ( depends on the material chosen which will be selected based on its cost and availability) Assuming a Factor of Safety of 3, = /3 Solving the above equation, the value of d was calculated as 22mm. Since tata aces drive axle satisfied our requirements we choosed it for our vehicle.

GEAR RATIOS Tyre circumference (R12) = 1592mm Differential ratio = 3.8:1 CVT max ratio = 0.43:1 Min ratio = 3:1

Engine max rpm = 3800

FOR SPEED MODE Calculation from engine towards wheels: Lets fix the top speed as 55 kmph (916 mpm). When the vehicle is at top speed the engine rotates at 3800 rpm. This will be increased to 8837 rpm by the cvt by the ratio 0.43:1 The gear box reduces this speed by the ratio X.

Calculated from wheels towards engine: To attain this speed the wheel should rotate at 575 rpm. (one rotation makes 1.59m) The input to differential will be at a speed of 2085 rpm The chain should have reduced the speed X to 2085rpm by the ratio Y.

By fixing the chain reduction as 2.5:1 we can find the gear ratio X. Input to chain drive = 2.5* 2085

=5213rpm gear ratio,X = 8837/5213 =1.695

Similarly for torque mode the gear ratio can be calculated, which is found to be 2.33:1 (max speed is taken as 40kmph) and for reverse it is 3:1

CLUTCH Since mahindra alfas clutch specifications satisfied our vehicle need we choosed it. Clutch plate D=10mm d= 4.5mm

GEARBOX Gear material- AISI 1018 Tensile strength-60000PSI (413.68 mpa) Yield strength- 40000PSI Brinell Hardness- 121

INITIAL TORQUE

Torque at wheels =

Briggs and Stratton Intek 20 Torque and Power

16 14 12 10 8 6 4 2 0 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 Torque (ft-lb) Power (hp)

Engine Speed (RPM)