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CHAPTER 1
INTRODUCTION
The project is about designing and fabricating a cost effective quad bike which will also be
more economic, safer and comfortable. Quad bikes of present time are having high cost and are
not at all easily available to the common persons or for military, forest ranger officials. In India,
goods which are available at lowest price will be the best option in market. The consumers are
more fond of the goods which are at lowest rate and having satisfactory features. The project is
primarily focusing to enhance the requirement of having an automobile support for the forest
rangers in the country as it helps them to travel and patrol on dense and rough terrains. The
government cannot provide quad bike for them as the available quad bikes in market are having
high rate which will be wasting up of money. For which this project is highly helpful and
convenient to the forest rangers. In many foreign countries they use quad bike for military
purposes, beach patrolling, adventure rides as for them they are not at all financially loss for them.
In India, the military officers, forest rangers are using conventional vehicles such as jeeps, bikes
etc. These vehicles are not compatible on some terrains such as jeep cannot be used in terrains
which are narrow, and highly rough areas. In case of bikes they are not compatible in steep, very
harsh roads where the rider has to place their legs for balancing so if we use quad bikes the vehicle
will be self-balanced. All these are the reasons where the project of low cost quad bike comes on
the help as the quad bike to be manufacture will have the feature to help in travel through difficult
terrains.
Fully functional and movable unit except the body consisting of all the systems mounted
on it is called as a chassis. And the most important component of the chassis is the frame. The
frame is the structure which is rigid in bending and torsion. The main purpose of the frame is to
make all the other subsystems constraint and fixed to work properly. It must be capable of
supporting all the components and occupants and should absorb all kinds of loads fed into it
without deflecting unduly. Also it should absorb the aerodynamic wind forces and road shocks
through suspensions.
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1
UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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Quad bike is a type of all-terrain vehicle which is mainly used for the transportation and
facilitate the need of a vehicle in rough terrain. Quad Bike is a type of ATV in which a rider can
sit and operate this vehicle like a Motorcycle. In India the use of quad bike is essential .In India
forest rangers, coast guards finds it difficult to travel through tough terrains. Most of the Quad bike
available in the market are not safe. Quad bikes available in the market is way too expensive over
1 Lakh. Safety has been a major issue with ATVs due to the high number of deaths and injuries
associated with them but our project provides safety to the riders. One of the main motto of our
project is to convert a conventional two-wheeler bike into an all-terrain four wheel bike in possibly
less time, cost with enough safety and comfort.
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2
UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 2
LITERATURE SURVEY
Mr. Srijan Manish etal. On the journal International Journal of Advanced Research in Engg.
& Tech. has made a study on Quad Bike Design and Simulation. In this study they are aiming at
making a Quad Bike. They have described the procedure they followed, methodology and their
considerations made in design process. They had made their own theoretical calculation and the
facts they have known about it. They have focused this paper on cheaper but Quality Quad Bikes
as a reference of industries, research etc. They have selected their engine by checking the
parameters so they have used a 1000cc engine. So they have generated a cost effective Quad Bike
to be designed. They have considered every fact they have studied, researched from the very small
section to every section of the Quad Bike.
Mr. Deep Shrivastava on his journal Design of All Terrain Vehicles has done a study on
ATV’s of single passenger. In order to achieve this he has checked different aspects of Quad Bikes
different vehicles were analyzed. During this process he made sure of consumers interest, cost
effectiveness of the bike was his main goal. He has specially concentrated on the chassis he has
made sure that chassis would withstand the parts plus drivers weight. The material for chassis was
4130 Chrome Moly steel because of greatest strength. The objective of single passenger ATV was
to ensure maximum safety with low cost which has been made possible. Design processes were
done in Solid Works, CATIA and ANSYS.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 3
DESIGN APPROCH
The task of designing began by conducting extensive research for the available species of
ATVs and quad bike and knowing its various technical where about. In here we are about to
convert a conventional two-wheeler bike into a quad bike by modifying the existing vehicle so that
we can get an effective quad bike. We are opting a way such that in converting a two-wheeler bike
to quad bike so there will be less money expense and less time consumption in fabricating it. For
the conversion we have changed some of the design features of the conventional vehicle to obtain
as per our needs. These design features are suspension, tyre, drive system, steering mechanisms.
Then keeping the voluminous data from our research in mind, the design on a CAD platform has
been implemented to achieve the best standardised as well as optimised design possible. SOLID
WORKS is the CAD software used for designing.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 4
FRAME
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 need 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.
The primary objective of the frame is to ensure driver’s safety, provide reliable mounting
locations for the engine and other vehicle components, be aesthetically appealing, low in cost, and
low in weight. Various considerations are taken into consideration to reflect the same. The
generated design through the SOLID WORKS software is as follows.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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The design is done by taking the basic design of the conventional two-wheeler bike and
adding more elements to the standard frame to enhance the ability of the frame and by this we can
have a more capable and durable design. By this we can have a suitable design for the required
features that is needed for the quad bike.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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Material selection of the chassis plays a crucial part in providing the desired strength,
endurance, safety and reliability to the vehicle. To choose the optimal material we did an extensive
study on the properties of different materials. We have finally selected AISI 1018 steel for our
fabrication works.
PARAMETER RESULT
Phosphorus ≤ 0.040 %
Sulphur ≤ 0.050 %
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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PHYSICAL PROPERTIES:
No PROPERTIES VALUES
1
Tensile strength, Ultimate
440Mpa
2
Tensile strength, Yield 370Mpa
3
Modulus of elasticity 205Gpa
4
Bulk Modulus 140Gpa
5
Shear Modulus 80Gpa
6
Poisson’s ratio 0.290
Table 4.2
We used AISI 1018 for our frame because of its best weld ability, machinability good
toughness and excellent elongation.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 5
SUSPENSION SYSTEM
The overall purpose of a suspension system is to absorb impacts from coarse irregularities
such as bumps and distribute that force with least amount of discomfort to the driver. We are doing
extensive research on the front and rear suspension arm’s geometry to help reduce as much body
roll as possible. Proper camber and caster angles will provided to the front wheels. The shocks will
be set to provide the proper dampening and spring coefficients to provide a smooth and well
performing ride.
For our front suspension we chose a Double arm wishbone type suspension. It provided
specious mounting position, load bearing capacity besides better camber recovery.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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MANUFACTURED PART:
The suspension was hand-made with the specified material that was selected for the
fabrication that was AISI 1018. The fabricated double wishbone is shown below:
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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DOUBLE WISHBONE:
In the rear part we are using the Monoshock type suspension attached to the swing arm
which is being used in Quad Bikes universally. Using Monoshock over dual shocks is
advantageous due to ease of adjustment as there is only single damping unit and smaller unsprung
mass.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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ACTUAL PART:
The rear suspension used is a monoshock suspension. This is actually the stock suspension
of the vehicle itself. A monoshock suspension system is used in the rear due to its wide variety of
advantages. Due to the load focusing in a single point which makes the system more comfortable.
It’s more stable due to the focus of load in a single point that too in the middle of the swingarm.
The stock rear suspension is shown in the figure below:
CHAPTER 6
BRAKING SYSTEM
The purpose of the braking system is to increase the safety and maneuverability of the
vehicle. In order to achieve maximum performance from the braking system, the brakes have been
designed to lock up the rear axle so it locks up the wheels at the same time. It is desired from a
quad bike that it should have effective braking capability to negotiate rigid terrains.
The braking system is composed of both internal expanding drum brakes and disc brakes.
The disc brake is mounted on the rear axle to satisfy the braking requirements of our quad bike
such as terrain of the track, speed limits, driver ergonomics and other rulebook constraints.
No. of Brake 1
Disc Outer Diameter 190mm
Disc Inner Diameter 30mm
Thickness 3mm
Brake Pedal Force 150N
Pedal Ratio 3:1
Coefficient Of Friction Pad 0.6
Stopping Distance 4.84m
Stopping Time 0.88sec
Total Brake Force 3187.8125N
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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At the time of braking, kinetic energy is converted into heat energy due to the friction
between calliper pad and rotor disc.
1
Kinetic Energy = 2 𝑚𝑣 2
2
= 250 x 11.11 /2
= 15429.0125 J
Deceleration of the vehicle should not exceed 1.3G.
µ = 0.6
Stopping distance of the vehicle is calculated by Newton Law's of motion.
2 2
v = u + 2aS
where,
v is the final velocity of the vehicle
u is the initial velocity of the vehicle
S is the stopping distance
2 2
S = v -u / 2a
2
= 11.11 /2x1.3x9.8
= 4.84 m
v = u + at
11.11= 1.3x9.81xt
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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FABRICATED BRAKE:
The fabricated brake system is of only rear disc brake system actuated by the foot pedal
as similar to that of a two-wheeler. The fabricated braking system is found to be working in good
condition and very much effectively. The figures that follow shows the brake in the quad bike.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 7
STEERING SYSTEM
The steering system is responsible for the overall direction of motion of the vehicle. In
accordance to basic automobile rules governing the drive of a two wheeler or a vehicle being
driven with a steering, it must be of mechanical links and must not be round or H-type.
The steering will be of hand le type with a bell crank mechanism at the en d of the steering
column. The steering column or stem will be made out of the same material as the rest of the
chassis. The tie rods for the steering will have knuckle joints to compensate for the suspension
jounce.
We researched and compared multiple steering systems. We need a steering system that
would be easy to maintain, provide easy operation, excellent feedback, cost efficient and
compatible to drivers ergonomics. So we have gone forward with the Ackermann steering
mechanism with bell crank lever method and the steering ratio is 1:1.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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𝞱� = 39.17⁰
= (1100/sin 39.17)/((1150-940)/2)
= 878.02 mm
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 8
ENGINE & TRANSMISSION
The engine that is using for the power production in the quad bike is of Honda 150cc
engine. We came to the decision of choosing the specified engine after studying and analysing
about different engines of many motorbikes. We decided to use the Honda 150cc engine as it is
having comparatively higher value of torque, power and lesser cost.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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8.2 TRANSMISSION
For the transmission of the power from the engine to the shaft is decided to be transmitted
with the help of chain drive transmission. The chain drive transmission is done by linking the
relative motion between the engine to the driving shaft by connecting chain from the engine side
to the shaft side by connecting the chain to the sprocket mounted to the shaft.
Chain drive transmission was selected for the transmission as this type is having the higher
transmission efficiency, speed ratio, less load on shaft, ability to transmit power to several shafts
by one single chain.
It can be operated under adverse temperature and atmospheric conditions. Since the chains
are made of material, therefore they occupy less space in width than a belt or rope drive. It may be
used for both long as well as short distances
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 9
TYRES AND RIMS
Traction is one of the most important aspects of both steering and getting the power to the
ground. The ideal tire has low weight and low internal forces. In addition, it must have strong
traction on various surfaces and be capable of providing power while in puddles.
Functions-
-Supports weight
-Transmit vehicles propulsion
-Soften impacts from roads
9.1 TYRES
We had kept in mind that our tyres should have a specific tread pattern so that it should
provide a strong and firm grip in all surfaces and can absorb any kind of depressions and bumps.
We have finalised the tyre specifications as 180/60 R13. 180mm is the width of the tyre, 60mm is
the aspect ratio and 13” is the rim diameter.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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9.2 RIMS
The Rims shall be made up of Aluminium to minimize unsprung weight. By reducing the
width of the rim the inertia will be directly decreased and subsequently this will also reduce the
overall weight. The diameter of all four rims will be 8 inches. To make our Design cost effective
we have customised our own rims.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 10
COST ESTIMATION
Our aim was to minimize the cost of the quad bike so that it could reach the hands of the
common people as the quad bikes available in the markets are of high cost. So we have clearly
managed each and every process of manufacturing of the quad bike from the tip to the bottom. We
purchased some of the parts and some were made in our workshop. Our cost estimation details are
given below.
TOTAL 22535
Table 10.1 Details of purchase
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 11
FUTURE SCOPE
The purpose of our project itself says that it is a cost effective quad bike we have designed
the vehicle in such a way that it is comfortable and affordable to all the common people and
government agencies such as forest rangers, beach patrols, police agencies etc. we also aimed for
the military use in the future by upgrading the existing vehicle into a continuous track or a
caterpillar track. This continuous track enables the vehicle to travel on very high tough terrains,
snowy, muddy etc.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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CHAPTER 12
CONCLUSION
The objective of this project is to design a cost effective quad bike which is also safe. After
going through many sources and with our own knowledge and personal experience we have come
forward with this design. The design works are done in solid works and a strong and rightful design
was obtained. Our other motto of converting a conventional two-wheeler vehicle to a quad bike
was achieved. The detailed description of the frame, suspension system, braking system, steering
system are taken into account in detail. The analysis and fabrication will be done in the next
semester. So by this report we conclude that the quad bike can be designed at low cost and ensure
safety.
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UKF College of Engineering & Technology, Paripally, Kollam
Design and Fabrication of Cost Effective Quad Bike
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REFERENCES
9) Roll cage of ATV IOSR (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 49-
53
10) Designing of ATV, Ijsrp, Volume 4, Issue 12, December 2014 1 ISSN 2250-3153
11) John C. Dixon; Suspension analysis and computation geometry; ISBN: 978-0-470-51021-
6; October 2009
13) Zhanwang, Y., and Zongyu, C., “Dynamic Response Analysis of Minicar Changan Star
6350”, Proceedings of 2nd MSC worldwide automotive conference, MSC, 2000
http://www.mscsoftware.com/support/library/conf/auto00/p02200.pdf
14) [Kim, H. S., Hwang, Y. S., Yoon, H. S., Dynamic Stress Analysis of a Bus
Systems”, Proceedings of 2nd MSC worldwide automotive conference, MSC,
2000. http://www.mscsoftware.com/support/library/conf/auto00/p03200.pdf
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UKF College of Engineering & Technology, Paripally, Kollam