1

RULEBOOK ABSTRACT 2
Parameters Rulebook Value Our Value

Length of ATV 108 inch 74.53 inch

Width of ATV 64 inch 59 inch

Helmet Clearance 6 inch 6.3 inch

Material with 0.18 % C ASTM-106 Grade-B with

Material of Rollcage
content 0.19% C content

Wheels Alignment 4 wheels must not be in same line

Shoulder Clearance 3 inch 4 inch

Rear Roll Hoop Inclination Max. 20o 15o

Distance of LDB members

Max. 5 inch 2 inch
from weld joints
Angle between FBM to
Max 45o 43.17o
vertical line
Brakes The braking system must be segregated into atleast
two independent hydraulic circuit
 TECHNICAL SPECIFICATIONS 3
• Height : 1250.0 mm •
Design Targets • Length : 1893.3 mm •
Ground Clearance: 330 mm
Wheel Base: 1600 mm
• Width : 850.0 mm • Track width (mm) : 1500(R) & 1400(F)
Roll cage
Car 300
weight Kg • Brake circuit :Diagonal • Deceleration :10.11 m/s
2

• Brake Diameter: 200 mm(F&R) • Pedal ratio: 6:1

Max. 58.38 • Stopping Distance(58 Km/hr.): 13m • Pedal force: 120N
Brakes • Stopping time(58 Km/hr.): 1.60 sec
speed Km/hr • Brake Force: 3221.72 N

Ground 330
• Type: Rack & Pinion • Caster Angle: +8o(F)
clearance mm • Steering Ratio: 16:1 • Camber Angle: -2o(F)
Steering • Wheel Base: 1600 mm • Toe Angle: 0o(F)
Turning 3.30 System
radius m
• Type: Double wishbone • Stiffness (N/mm) : 11.15(F) & 18.59(R)
Max. 6.13
• Spring: Concentric Springs • Free length (mm) : 285(F) & 334(R)
acceleration m/s2
Suspension • Deflection: 136 mm • Damping Ratio: 0.83(F) & 0.76 (R)

Stopping 8.29
distance m • Transmission System: Manual OEM • Gradeability : 46.99%
• Maximum Speed: 58.38 Km/hr. • Tractive force: 1963.15 N
Stopping 2.64
• Maximum Acceleration: 6.13 m/s2
time sec Power
train
2D/3D VIEWS OF THE ATV & ITS PARTS 4
Roll Cage A-Arms & Springs Final ATV
Knuckles
CONCENTRIC
FINAL DESIGN FRONT SPRINGS

FRONT

REAR
FIRST DESIGN SIDE

TOP
ROLL CAGE ANALYSIS 5
Frontal Impact
1) Load: 4g
2) Stress: 70 MPa
3) Deformation: 1.01 mm
4) F.O.S: 3.43

Rear Impact
1) Load: 4g
2) Stress: 80 MPa
3) Deformation: 2.14 mm
4) F.O.S: 3.0

Side Impact
1) Load: 1g
2) Stress: 110 MPa
3) Deformation: 2.86 mm
4) F.O.S: 2.20
 Roll Over 6
1) Load: 1g
2) Stress: 52 MPa
3) Deformation: 0.30 mm
4) F.O.S: 4.63

Torsion
1) Load: 1g
2) Stress: 76 MPa
3) Deformation: 0.76 mm
4) F.O.S: 3.15

Bump
Modal 1) Load: 1g
1) Frequency: 41.97 Hz 2) Stress: 170 MPa
2) Deformation: 14.1 mm 3) Deformation: 5.33 mm
4) F.O.S: 1.4
ERGONOMICS 7
 SUSPENSION 8
REAR
PARAMETER FRONT REAR
Double Wishbone Double Wishbone
Type of suspension
with unequal lengths with unequal lengths
Ground clearance 330 mm 300 mm

Tyre size 635 mm outer dia. 635 mm outer dia.

Max vertical wheel 177 mm up & 127 127 mm up & 100
travel mm down mm down
Suspension ratio 0.46:1 0.61:1

Anti-dive 13.43% - Minimum F.O.S: 4.4

Anti-squat - 13.09% FRONT
Camber -2 -2

Caster 8 NA

Kingpin Inclination 12o NA

Mech. Trail or
44.62 mm NA
Caster Trail
Scrub Radius 24.09 mm NA
 SUSPENSION(LAYOUT) 9
FRONT REAR

Consideration Priority Reasons

FRONT SUSPENSION
Simplicity Essential This is a main goal of the team overall
Light weight Essential Weight is the number one enemy of a race car, especially sprung weight
High Turning and stopping both require contact between the tyre and the ground, which
304 mm of Travel
is achieved through travel
Durability High Withstand abusive-driving during the endurance race
Shock Absorbing Desired Frontal impact cause a heavy amount of damage to the car
Compatible with Steering
REAR SUSPENSION
Simplicity Essential Easier to fix, build, design, analyze
Lightweight Essential Less weight is essential to be competitive
227 mm Travel High Allows tyre to be on the ground situations and still have traction
Durability High Withstand abusive-driving during the endurance race
 CONCENTRIC SPRING 10
Parameters Front Rear
Inner Outer Inner Outer
Wire diameter (mm) 6 8 6 9
Coil diameter (mm) 54 72 54 81
Active coils 22 14 29 17
Total coils 24 16 31 19
Load (N) 571.92 945.39 953.31 1575.82
Stiffness(N/mm) 4.20 6.95 11.58 7.01 Maximum Shear Stress: 457 MPa
Clearance between springs
3 6
(mm)
Deflection of Spring: 136 mm
Deflection of spring (mm) 136 136

Critical damping
1776.17 2778.84
value(body) (Ns/m)
Critical damping 2412.75 2492.78
value(wheels) (Ns/m)

2528.68 7255
Wheel rate (N/mm)
Critical damping force (Cr) 1826.35 3095.81
(N)
Damping Ratio 0.83 0.79
 STEERING 11
STEERING SYSTEM : 2 Wheel steering System
(OEM)

Two Wheel Steering

System layout

Scrub Turning
Track Steering Mechanical
Wheelbase radius: C-Factor: Radius: 3.3 m
width: Ratio: trail: 44.62
1600 mm 24.09 33 mm
1400 mm 16:1 mm (outer Front)
mm
 STEERING SYSTEM 12
COMPONENTS TRUE ACKERMANN GEOMETRY

1) Steering arms
2) Tie rods
3) Track rod
4) Rack and pinion
5) Steering wheel
Formulas for 2 wheel
steering system:
e 1 1
 
l tan( ) tan( ) e= Distance between two tie rods ends
l be l= Wheel base
Rif =  
sin   2  b= Track width (F)
∅= Inner wheel lock angle
l be ф= Outer wheel lock angle
Rof =  
sin   2  Rif= Radius (inner front)
l be Rof= Radius (outer front)
Rir =  
tan   2  Rir= Radius (inner rear)
 BRAKES 13
Components
• All 4 Disc combination used to STATIC LOAD DISTRIBUTION
achieve 4 Wheel Lock.
Front Axle Load 808.5 N
• Disc Used –200 mm (OEM) Rear Axle Load 1347.5 N

• Master Cylinder Used – (OEM)

DYNAMIC LOAD DISTRIBUTION
Remarks
• This particular combination of Front Axle Load 1537.57 N
Calipers is chosen due to its Ease of
Mounting Bleeding points on top. Rear Axle Load 618.42 N

• Diagonal Braking Circuit Split used

so that braking power is available on
both Axles in case one Circuit Fails. During Max .Acceleration 6.13 m/s2
Dynamic Front Axle
366.44 N
Load
Dynamic Rear Axle
1789.55 N
Load
 14
BRAKE
CIRCUIT • Total weight of vehicle is 300 kgs
• Load on front axle is 37.5%
• Load on rear axle is 62.5%

Type of brake used Disc Brake

Front 200 mm
Rear 200 mm
1 tandem master
Master Cylinder
cylinder
Brake circuit Diagonal type
Brake Force 3221.72 N
Stopping distance
13 m
(58 km/hr.)
Deceleration 10.11 m/s2
Stopping time
1.60 sec.
(58km/hr.)
Pedal force 120 N
Pedal ratio 6:1
 POWER TRAIN 15
Torque (ft-lbs, 14.50
gross)
MAX. TORQUE AT Engine 305
2600 RPM Displacement
(cc)
ENGINE SPECIFICATION
Number of Single
Cylinders
Engine Horizontal
Configuration Shaft
TYRES • Duro -Power Grip ATV Tyres
Engine OHV
• Dimension : 25x8-12 ;
Technology
6 Ply Rating
• This tyre is radial constructed that Length (in) 12.3
designed to help alleviate the hard Width (in) 15.4
impact when riding riding on rough Height (in) 16.4
terrain with pits & gravel & boost Weight (lbs) 50.4
driving comfort. Bore (in) 3.12
• Innovative sidewall & ply structure Stroke (in) 2.44
aids in protecting the tyres from Engine Fuel Gasoline
punctures , protect the rim & boosts Spark Plug RC12YC
the life of tyre
 DESIGN METHODOLOGY OF TRANSMISSION 16
Transmission System: 2 Wheel Rear Drive ATV

Quantity
Gear 1st 2nd 3rd 4th Reverse

Gear Ratio 31.48 18.7 11.4 7.35 55.08

Velocity(m/s) 3.8 6.41 10.52 16.31 2.07

Acceleration
6.13 3.63 2.21 1.42 10.70 Gear Box :
(m/s2)
4 Forward and 1 Reverse
Tractive force(N) 1963.15 1163.80 709.12 457.10 3425.51 (OEM)
 COST & WEIGHT REPORT 17
Team Effort’s Cost Report

Total Weight: 300 Kg Total Cost of ATV: Rs. 2,32,000

OUR SPONSORS
MS PROJECT PLAN 18
 Potential
DFMEA 19
Design Potential failure Potential effect(s)
cause(s) of S O D RPN Preventive actions
Parameter mode(s) of failure
failure
Bending and
Roll Cage Impact load High risk to driver 9 1 5 45 High factor of safety
buckling
Impact load
Failure of Power Provide sufficient deflection
Axle shaft Bending and fracture and excess 6 2 3 36
train and damping to suspensions
wheel travel
A-arms Bending 5 1 4 20 High factor of safety
Torsional Shear Failure of
Static and 6 2 4 48 Use Concentric Springs
Spring and/or Buckling Suspension and
Dynamic load
Direct Shear and Steering System
7 1 6 42 High Factor of Safety
Knuckle Bending
Bending of rod Front impact
Failure of Steering Provide sufficient deflection
Tie rod and/or fracture of and excess 5 2 2 20
System and damping to suspensions
ball-joint wheel travel
Master Loss of hydraulic Leakage in Failure of Braking Use hose material with higher
7 2 3 42
Cylinder fluid hose System strength
Theoretical Actual
Testing part/Equipment Method
Value Value
DATA Ground clearance Measurement by Steel Ruler 13 inch
VALIDATION Stopping Distance Measurement by Measuring tape 11m
Speed Using Stopwatch 58.8 Km/hr.
PLAN
Turning Radius Practically (Figure test; Measuring tape) 3.3m
Steering Ratio Protractor 16:1
 MANUFACTURING PROCESS 20
Processes which Team is going to use for Fabrication
Cutting Process Hacksaw Machine cutting
Drilling Process Drilling Machine
Turning Process Lathe Machine
Bending Process Bending Press
Welding Process Manual Metal Arc Welding
Grinding Process Grinding Machine

WORKSHOP FACILITIES
 TEAM ORGANIZATION 21
Chitralekha N. Vyom Makani Design Team
(Faculty Advisor) (Vice Captain)

Power Roll Steering

Suspension Brakes
Train Cage System

Parth Kevin Hanee Aniket Nikhil Sahil Samay Vyom Pranav Nikhil Jay
S. C. Patel Patel G. Bali Patel Makani Mehta G. Vyas

Sunny Utsav Divyansh Samay

MARKETING Utsav B.
Patel Shah U. Patel

Kamlesh S. Samay Fabrication & Logistics Team

(Faculty Advisor) Patel(Captain)

Roll Steering Power

Suspension
System Brakes
cage Train

Pathik Aditya Ruchik Hanee Jay Amit Avnesh Bhavik Milind Jay
Patel Dave Raval Patel Vyas Dev Rawat Purohit Kadiya Joshi
22