TWO WHEEL DRIVE OFF-ROAD MOTORCYCLE

Project Report

Submitted in partial fulfillment of the requirement

for the award of the Degree of Bachelor of Technology
In Mechanical Engineering from The
University of Kerala during the Academic Year 2017-18
Submitted by project team
ADAM IND
BIBIN MATHEWS VARKEY
JOHN JOSEPH
KEVIN JOSEPH PEREIRA
SHIBIN BINNY
S8, Mechanical Engineering Dept.

DEPARTMENT OF MECHANICAL ENGINEERING

ST. THOMAS INSTITUTE FOR SCIENCE AND TECHNOLOGY
THIRUVANANTHAPURAM
2017

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 DEPARTMENT OF MECHANICAL ENGINEERING
ST. THOMAS INSTITUTE FOR SCIENCE AND TECHNOLOGY

Certificate

This is to certify that the project report entitled ‘Two wheel drive off-road motor cycle’ is a
bona-fide report made by ADAM IND (14434002), BIBIN MATHEWS VARKEY (14434023),
JOHN JOSEPH (14434033), KEVIN JOSEPH PEREIRA (14434035), SHIBIN BINNY
(14434052) of S8 Mechanical Engineering. This report is submitted in partial fulfillment of the
requirement for the award of the Degree of Bachelor of Technology in Mechanical Engineering
from the University of Kerala during the academic Year 2017-18.

Certified by Approved by

Ayyappadas G Dr. Rag R.L

Assistant Professor Professor & Head
Department Of Department Of
Mechanical Engineering Mechanical Engineering

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 ACKNOWLEDGEMENT

First and foremost, with a bowed head we offer our heartfelt prayers to the Almighty god
with outmost humility for His continued grace and mercy on we to conquer this milestone.

We avail this opportunity to extent hearty indebtedness to our guide Mr. Ayyappadas G,
Assistant professor Mechanical Engineering Department, for his valuable guidance, constant
encouragement and kind help at different stages for the execution of this work.

We are grateful to Mr. Ashish Zachariah, Assistant professor Mechanical Engineering

Department, staff advisor and seminar coordinator for his guidance and wholehearted support
throughout.

We also express our sincere gratitude to Dr. Rag R L, Head of the Department,
Mechanical Engineering, for critical review and technical assistance for making this report.

We are extremely grateful to our parents and our whole family for showering their love,
inspiration, emotional support, understanding, persistence, prayers and endless encouragement to
pursue this work and for making this pursuit worthwhile.

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ABSTRACT

Uses of two wheelers /motorcycles are very common in developing countries across the globe. In
most developing countries motorcycles are employed for day to day transportation through areas
where there are no proper ways to travel (off road). Main objective of our project “Two Wheel
Drive Motorcycle” is to provide better traction over such areas. By providing drive to the front
wheel with the help of An Induction Motor the power is transmitted with the help of chain and
sprockets system, drive through off road conditions are aided for the better. With the use of
induction motor the load on conventional Internal Combustion engines are greatly reduced too.
By adopting this method, saving of scarce fossil fuel can also be done effortlessly. The motor can
also be used alone in emergency situations. This can be used if the engine runs out of fuel or
breaks down. The implementation of this system will allow easier travel for people in rural areas
where 2 wheelers are used for various applications like carrying heavy loads or more than 2
people etc, Also the torque from the electric motor will help from getting out of potholes if the
motorcycle gets stuck.

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CONTENTS

Chapter No: Contents Page No:

1 Introduction
1.1 General 1

2 Literature Review
2.1 2 Wheel Drive Motorcycle 3
2.2 History 3
3 Study On Mechanism And Working
3.1 Shaft Drive Mechanism 6
3.2 Belt Drive Mechanism 7
3.3 Chain And Sprocket Mechanism 9
3.4 Torque Converter Mechanism 10
3.5 Basic Working 11
4 Report On The Present Investigation
4.1 Components Used 12
4.2 Basic Design 18
4.3 Working 19
4.4 Output Calculation 20
4.5 Materials Used 21
4.6 Operations In Our Project 24
5 Results And Discussions
5.1 Discussions 27
5.2 Result 28
6 Summary And Conclusions 29

7 References 30

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LIST OF FIGURES

Sl No Description Page No:

1 3.1 Shaft Drive 6
2 3.2 Belt Drive 8
3 3.3 Chain Drive 9
4 4.1.1 Motor Schematics 13
5 4.1.2 Motor 13
6 4.1.3 Battery 15
7 4.1.4 Motor Controller 16
8 4.1.5 Throttle 17
9 4.2 Motor Mount Design 18
10 4.3 Completed Assembly 19
11 4.6.1 Turning 24
12 4.6.2 Facing 25
13 4.6.3 Drilling 26
14 4.6.4 Disc Drilling 26

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CHAPTER 1

INTRODUCTION

Even before the beginning of civilization human beings are prone for expedition, there begins
the inventions and innovation of different ways of travel. At first they began to travel from one
point to another by physically, also had to carry things physically too. When physical travel
became tiring they began to employ animals for sufficient travel but as they were insufficient to
accommodate more than one than two beings at a time so then the invention of wheels and cart
made of wood came to be, so they can accommodate more than two at a time or some other
commodities. After the carts and wheel made of wood/timber outdated then came wheels and
cart of metal, then when the animals used to pull the cart were replaced by engines which could
pull the cart according to our need, then came to be automobiles.

The invention of automobiles revolutionized the living and travel habit of human beings. They
begin to challenge themselves by the capability of the machine and human, by making the
automobile to reach anywhere, and then begin to race, to challenge the speed limit. Human
Beings now days use automobiles not only a means to travel or get from a point to another, but to
have fun. As the needs of Human Beings began to expand for the use of automobiles came in
different vehicles with different purposes.

The invention of bicycle was revolutionary because with the bicycle a rider could get anywhere
with the effort. As the effort needed to put in for the ride causes fatigue, then came in the
invention of motorcycle. Now day‟s motorcycles are undeniable presence in our day to day life.
When we study about motorcycles there are different types/ categories of motorcycles such as
Adventure Touring Bikes / Dual Sports, Choppers, Cruisers, Dirt bikes, Enduro bikes, Motocross
bike, Naked bikes, Power Cruisers, Power Scooters, Scooters, Sports bikes, Supermoto bikes,
Touring bikes, Trial bikes, Commuters etc. Each motorcycles has its own properties according to
is use. As there are these many categories of motorcycles, developing countries are opting for
category of motorcycle which is practically cheap.

That is why we can observe that the use of commuter bikes in developing countries are very
much greater than in any other countries, because they are cheap can get you where you want to

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go and gives high mileage. By all these we can observe the commuters likely to be in any
compromising position such as stuck in mud or unable to climb steep slope etc. that is because of
unavailability of basic infrastructures. As to escape from these compromising positions the
vehicles will exert more abuse on the engine which will cost the rider economically.

All the Internal Combustion Engines used in all the machineries uses refined fossil fuels which
are likely to be depleted completely soon, therefore now days researches are being done for
alternate energy source as well as employing hybrid technologies etc. now days cars and
motorbikes are powered by electric motors. But they are not common since many can‟t afford
them.

Now we are discussing our new and innovative concept that is, two wheel drive motor cycle. By
employing a DC motor to the front wheel of the commuting motorbike it will provide necessary
assist when a normal commuting motorbike finds compromising such as being stuck in ditches or
mud, or at climbing very steep slope. Since we are using a DC motor which is powered by the
battery we can save the conventional fuel using in the motorcycle. This is the main idea of the
project.

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CHAPTER 2

LITERATURE REVIEW
2.1 TWO WHEEL DRIVE MOTORCYCLE

For making off-road situations easier we power the front wheel of the motorcycle along with the
rear wheel. This will help by providing better traction in harsh conditions . This system is known
as “Two wheel drive motorcycle”.

2.2 HISTORY

In cars, the power is transmitted mechanically to the wheels by driveshaft but in the case of a
motorcycle, there are some difficulties in transmit power to the front wheel. Because The hub of
front wheel of a bike is surrounded by the fork legs, and in certain cases by double discs, making
the hub even more difficult to reach. The 2-Trac system uses a hydraulic pump located above the
gear box, and driven by a chain (in an oil bath) driven from the gear box.

The system comprises a pump connected by flexible hoses to a hydraulic engine located in the
hub of the front wheel. The 2-trac is a closed loop system equipped with filtration system and is
a self-regulated compact unit. The hydraulic pressure transmitted to the front wheel is
proportional to the speed of the rear wheel: the more the rear wheel loses traction, the more the
hydraulic system compensates by increasing the traction power to the front wheel. The
distribution of the power between the front and rear wheels is variable in order to optimize
traction. The front wheel can never turn quicker than the rear wheel, and the power transmitted to
the front wheel is never higher than that used for the rear. This self-regulated system also allows
for the conditions, so that the power to the front wheel is slowly reduced so that the rear wheel
"recovers" traction.

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When the throttle is closed, no power is transmitted to the front wheel, but if the throttle is
opened abruptly and that the rear wheel starts to lose grip, the sudden increase in pump revs
increases the hydraulic pressure of the system and a higher proportion of engine power is
transmitted to the front wheel. If the rear wheel continues to spin, more power is sent to the front
wheel. The proportion of the engine power provided to the front wheel is hence controlled by
both the throttle and the traction of the rear wheel. There are two ways for transmit power to the
front wheel mechanical and hydraulic.

The majority of the prototypes used a mechanical drive by chain or gears connected to the front
wheel. This is heavy and complex and required high maintenance. Another problem associated
with mechanical systems is that fitting them required complex modifications to the frame and
suspension.

Mechanical All Wheel Drive system delivers power from the motorcycle transmission to the
front wheel through a series of chains and shafts. There is no hydraulics used.

The mechanical system works similar to that of AWD systems found on four wheeled vehicles.
The use of one-way clutches in the front hub allows the front wheel to be driven at a slightly
slower rate than the rear wheel. Power is transferred to the front wheel only when the rear wheel
loses traction or the front wheel skids. The front-to-rear power ratio is adjustable with a simple
sprocket adjustment. This helps in fine tuning of the AWD system to suit riding conditions and
personal riding preferences
A handlebar-mounted switch controls the AWD “shift on the fly” clutch. When the clutch is
engaged, the rear spiral gear interlocks with the rear hub and power is transferred via internal
shafts to the forward spiral gear set, which drives the CHRISTINI free hub.(front hub)

the front wheel is not actively powered on smooth level grounds. And when the rear wheel slips,
the power is instantaneously transferred to the front wheel. Similarly, the moment that the front
wheel decelerates, as in hitting a rock or starting to wash out in a corner, power and traction are
transferred to the front wheel. This is how the 2 wheel drive system by Christini works.

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Currently available 2wd motor bikes directly or indirectly uses the power developed by the ic
engine to drive the front wheel via complex gearing and shaft to transmit power and losses are
present. And complex modifications are to be done for fixing the hub, shaft and bevel gears to
the front end of the bike and weight of the vehicle also increases

In our project the technique we use is simple and easy to install and there is no need of complex
modifications, a dc motor which is mounted on the mount provided between the fork legs drives
the front wheel using chain drive. The dc motor is powered by a separate battery of suitable
output, the front wheel works even if the ic engine is not ignited i.e. it works in standalone
conditions. A one way clutch is fixed on the front wheel using nut and bolts (2 circular plates are
fixed on the either sides of the hub to impart firmness).The mount is made of stainless steel

Maintenance is a lot easier on our system because electric motors have minimum moving parts
and requires almost no maintenance unlike mechanical systems . Our system is also a lot easier
to implement on a motorcycle in comparison.

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CHAPTER 3
Study On Mechanism And Working
Here we can use 3 mechanisms for power transmission , They are :

1) Shaft Drive Mechanism

2) Belt Drive Mechanism

3) Chain and Sprocket Drive Mechanism

4) Torque Converter Mechanism

3.1 SHAFT DRIVE MECHANISM

A drive shaft is a mechanical component for transmitting torque and rotation, usually used to
connect other components of a drive train that cannot be connected directly because of distance
or the need to allow for relative movement between them.

Figure 3.1

As torque carriers, drive shafts are subject to torsion and shear stress, equivalent to the
difference between the input torque and the load. They must therefore be strong enough to bear
the stress, while avoiding too much additional weight as that would in turn increase their inertia.

To allow for variations in the alignment and distance between the driving and driven
components, drive shafts frequently incorporate one or more universal joints, jaw couplings, or
rag joints, and sometimes a splined joint or prismatic joint. Using a shaft drive in our project will

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require more space and time. Also the losses in a shaft drive mechanism are comparatively
higher when compared to belt and chain drives so we decided to not use the shaft drive
mechanism.

Advantages:

• Drive system is less likely to become jammed

• The rider cannot become dirtied from chain grease or injured by "Chain bite"
when clothing or a body part catches between an unguarded chain and a sprocket.

• Lower maintenance than a chain system when the drive shaft is enclosed in a
tube.

• More consistent performance. Dynamic Bicycles claims that a drive shaft bicycle
can deliver 94% efficiency, whereas a chain-driven bike can deliver anywhere from 75-
97% efficiency based on condition.

Disadvantages:

• A drive shaft system weighs more than a chain system, usually 0.5–1 kg (1–2 lb)
heavier.

• Many of the advantages claimed by drive shaft's proponents can be achieved on a

chain-driven bicycle, such as covering the chain and gears.

• Use of lightweight derailleur gears with a high number of ratios is impossible,

although hub gears can be used.

• Wheel removal can be complicated in some designs (as it is for some chain-driven
bicycles with hub gears).

3.2 BELT DRIVE MECHANISM

A belt is a looped strip of flexible material used to mechanically link two or more rotating shafts.

A belt drive offers smooth transmission of power between shafts at a considerable distance. Belt
drives are used as the source of motion to transfer to efficiently transmit power or to track

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relative movement. Here we didnt consider using belt drive because of the thickness of the belt is
harder to implement. There is also a chance of slippage because of the sudden torque provided
by electric motors.

Figure 3.2

Advantages:

• Belt drives are simple and are economical.

• They don‟t need parallel shafts.

• Belts drives are provided with overload and jam protection.

• Noise and vibration are damped out. Machinery life is increased because load
fluctuations are shock-absorbed.

• They are lubrication-free. They require less maintenance cost.

Disadvantages:

• In Belt drives, angular velocity ratio is not necessarily constant or equal to the ratio of
pulley diameters, because of slipping and stretching.

• Heat buildup occurs. Speed is limited to usually 35 meters per second. Power
transmission is limited to 370 kilowatts.

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• Some adjustment of center distance or use of an idler pulley is necessary for wearing and
stretching of belt drive compensation.

3.3 CHAIN AND SPROCKET DRIVE MECHANISM

Here, the power is conveyed by a roller chain, known as the drive chain or transmission chain,
passing over a sprocket gear, with the teeth of the gear meshing with the holes in the links of the
chain. The gear is turned, and this pulls the chain putting mechanical force into the system.

Figure 3.3

Sometimes the power is output by simply rotating the chain, which can be used to lift or drag
objects. In other situations, a second gear is placed and the power is recovered by attaching
shafts or hubs to this gear. Though drive chains are often simple oval loops, they can also go
around corners by placing more than two gears along the chain; gears that do not put power into
the system or transmit it out are generally known as idler-wheels. By varying the diameter of the
input and output gears with respect to each other, the gear ratio can be altered. Here we use chain

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drive mechanism for driving the front wheel by connecting the front sprocket to the motor with a
ratio 2:1.

Advantages:

• Chances of slippage occurring is lower

• Since the chains are made of metal, 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.

• It gives a high transmission efficiency (upto 98 percent).

• It transmits more power than belts.

• It can be operated under adverse temperature and atmospheric conditions.

Disadvantages:

• The chain drive needs accurate mounting and careful maintenance

3.4 TORQUE CONVERTER MECHANISM

In this mechanism, spur gears are employed which can be used to increase the overall torque
output while reducing the speed of the motor considerably. Therefore we can se this t match the
torque of the engine with the motor which allows for smooth and equal torque distribution
between the wheels.

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3.5 BASIC WORKING

First the system is switched on by using the switch on the handlebar. The motor can then be
operated using the throttle mechanism . The motor is connected to the freewheel, which will
disengage if the wheel spins faster than the motor speed. This way there won‟t be any
interference between the two. Thus the motor will only send power if the front wheel spins
slower than the motor speed. The system is turned off using the switch again and the motorcycle
will work normally, running only on the main engine.

The system is designed to work only in situations where traction is low for better control and
grip. But in emergency situations, we can use the motor independently without the help of the
motor. Here the motor will be able to pull the motorcycle at least 2.5 km at a maximum speed of
20kmph. The batteries will be charged when the engine is running through the stator already in
the motorcycle.

The batteries can also be charged using an external charger if required. Or in situations where
the charge is too low.

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CHAPTER 4
REPORT ON THE PRESENT INVESTIGATION

4.1 COMPONENTS USED

4.1.1 MOTOR
Motors are machines which converts electrical energy into mechanical energy. It employs
Faradays Law of Electromagnetism which states that “Whenever a conductor is placed in a
variable magnetic field or moving conductor in a magnetic field, an emf is induced on the
conductor”. Also when a current carrying conductor is placed in a magnetic field, a force is
experienced by the conductor, this is the principle of motor.

There are different types of motors classified as:

 Alternating current(AC motor)

 Direct current (DC motor)
.Induction motor (normal type)
.Wheel Hub motor (special type)

Wheel Hub Motor (also called as hub motor) is an electric motor that is incorporated in to hub of
a wheel and drives it directly.

Working: Electromagnetic fields are supplied to the stationary windings of the motor, the outer
part of the motor follows or ties to follow those turning the attached wheel.

It can transmit power without any extra power transmission units like, chain/belt/shaft/.
Automobiles are employing these motors but hub motors are expensive on comparison with
normal induction motor. Hub motors are better variant than current implanted motor, but hub
motors are expensive on comparison. Working of induction is almost similar but here
electromagnetic field is applied to the rotary windings. Here rotary motion is taken out from a
shaft and power is transmitted with the aid of power transmitting units.

Here we are using DC motor (MY 1016 motor) instead of Hub motors because it is cheaper and
easily obtainable.

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MY 1016 MOTOR

Figure 4.1.1

Figure 4.1.2

Specifications:

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  Induction DC motor
 Voltage: 24Volts
 Power: 350W
 Current: 19.2Amps
 Torque: 11 Nm
 Speed: 300 Rpm
 Efficiency: less than 75%
 No. of teeth: 9 teeth sprocket fixed on

4.1.2 BATTERY
Batteries are device which consists of one or more cells, in which energy is stored as
chemical energy, which is converted into electrical energy to use it as a power source. Types
of batteries available in the market are as follows:

 Lithium-ion battery
 Lead acid battery

A lithium-ion battery (Li-ion) is a type of rechargeable battery in which lithium ions move
from negative electrode to the positive during discharge and back when charging. Li-ion
batteries use an intercalated lithium compound as one electrode material, compared to the
metallic lithium used in a non-rechargeable lithium battery. The electrolyte, which allows for
ionic movement, and the two electrodes are the constituent components of a lithium-ion
battery cell.

A lead acid battery is the oldest type of rechargeable battery. Despite having very low
energy-to-weight ratio, its ability to supply high surge currents means that the cells have a
relatively large power-to-weight ratio. These features, along with their low cost, make them
attractive for use in motor vehicles to provide the high current required by automobile starter
motors.

Differences between Lead acid and Lithium-ion batteries:

 Weight: Lithium-ion batteries are one-third the weight of lead acid batteries.

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  Efficiency: Lithium-ion batteries are nearly 100% efficient in both charge and
discharge, allowing for the same amp hours both in and out. Lead acid batteries „in
efficiency leads to a loss of 15amps while charging and rapid discharging drops
voltage quickly and reduces the batteries‟ capacity
 Discharge: Lithium-ion batteries are discharged 100% versus less than 80% for lead
acid. Most lead acid batteries do not recommend more than 50% depth of discharge.
 Cycle Life: Rechargeable lithium-ion batteries cycle 5000times or more compared to
just 400-500 cycles in lead acid. Cycle life is greatly affected by higher levels of
discharge in lead acid, versus only slightly affected in lithium-ion batteries.
 Voltage: Lithium-ion batteries maintain their voltage throughout the entire discharge
cycle. This allows for greater and longer-lasting efficiency of electrical components.
Lead acid voltage drops consistently throughout the discharge cycle.
 Cost: Despite the higher upfront cost of lithium-ion batteries, the true cost of
ownership is far less than lead acid when considering life span and performance
 Environmental Impact: Lithium-ion batteries are a much cleaner technology and are
safer for the environment.

Here we use Lead acid batteries because it is comparatively cheaper and easily available

Figure 4.1.3

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Specifications:

 Voltage: 12Volts
 Capacity: 24Amps hour
 Weight: 8Kg
 The batteries are charged from the IC engine (stator)

4.1.3 MOTOR CONTROLLER

Motor controller is a device which controls the speed of motor by the help of controller circuit. It
is already programmed and ready to use. A motor controller is connected to a power source such
as a battery pack or power supply, and control circuitry in the form of analog or digital input
signals.
Specification
• Rated Voltage: 24 Volts

• Rated current:28 Amps

• Rated power:500 Watts

Figure 4.1.4

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4.1.4 THROTTLE
It is a governing device, which is used to control the speed of motor by physical means like
twisting the throttle bar.
Specification
 Voltage :24 Volts
 Current : 2.4 Amps

Figure 4.1.5

4.1.5 SPROCKET WITH FREWHEEL

We use a 16 teeth sprocket with a freewheel attached for connecting to the front wheel and thus
transmit power

4.1.6 FRAME AND OTHER MISCELLANEOUS COMPONENTS

• We are using a mount for supporting the motor.

• Planning to keep the motor attached to the fork of the front wheel near to the hub.

• Connection cables used are standard cables used in motorcycle wiring

• We use stainless steel plates , discs and mild steel flat bars for the fabrication process

• A compatible chain is used between the sprockets

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4.2 BASIC DESIGN

Figure 4.2

In out basic design, we connect out fabricated motor mount to the front fork of the motorcycle
using the bolts for the mudguard. Reinforcement bars are added which help in absorbing more
stress and will also help in stability and during sudden shocks. The sprocket is connected to the
front wheels using blank discs fabricated specially for mounting the sprocket. The chain is
connected between the two

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4.3 WORKING

We mounted a DC motor of 350watt, 2250rpm producing 3Nm with a torque converter to

produce 11Nm torque and reduced to 300rpm which is our required torque. This motor assembly
is assembled on a custom made mount of stainless steel according our specification to the fork of
the motorcycle; this mount is reinforced with support bar to the axle of the front wheel.

The torque is transmitted to the front wheel with the help of a chain drive. Sprocket is welded to
a blank disk which is fastened to another disk on the other side of the front wheel with the help
of bolts and nuts. In order to protect the motor from the excessive rotation from the front wheel,
it is connected through a free wheel. When the system is actuated DC motor draws power from
the two batteries connected in series, the motor controller controls the supply to the motor by the
help of a throttle which basically a potential meter. When the throttle is turned sufficiently,
motor controller senses and adjusts the power supply to the motor and rpm is controlled, since
it‟s an electric motor it will provide constant torque which will be converted to our preference by
torque converter. The chain meshing the sprockets transfers the torque to the front wheel to attain
our desired process of two wheel drive motorcycle.

Figure 4.3

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4.4 OUTPUT CALCULATIONS

BATTERY AND RANGE

Calculations biased on battery and DC motor.

Capacity of Battery = 7 Ah
Voltage of Battery (2 in series) = 24v
DC Motor Specification
Speed of motor before reduction = 2250rpm (rated speed)
Speed of motor after reduction = 300rpm (maximum speed)
Rated Voltage of the motor = 24v
Rated Power of the motor = 350W
Rated Current of the motor = 19.2A
Period of ride on motor alone =7Ah÷19.2A
=0.3645h=21.82 min
That is, motor will last for 21.82 minutes of ride on fully charged battery.
Radius of the wheel used in bike =21 inch =0.5334 meter
Perimeter of circle =2πR= 3.35m = 0.00335km
That is the wheel has to turn 298.5 ~ 300 rotations to cover 1 km.
Note: 300rpm is the maximum rotation speed of the motor after speed reduction, when
calculating as only 78% of the speed is considered because efficiency of motor is 78%. That is
78% of 300rpm = 234rpm.
Maximum speed can attain by the vehicle on motor load alone (Assuming speed of motor =
467rpm [considering sprocket reduction ratio, 1.77]) =14.95km/hr.
(From equation (rpm/wheel radius)*(60/1000) =Speed in km/hr.)
Maximum distance of travel using motor load alone [max. speed of vehicle*period of ride] =5.43
km.

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4.5 MATERIALS USED

4.5.1 MILD STEEL

Mild steel is a commonly used material, mainly available as bars, discs etc. It is easily available
in the market and is mainly considered for its various advantages.
Chemical Composition
Carbon, C: 0.25-0.29 %
Copper, Cu: 0.20%
Manganese, Mn: 1.03%
Iron, Fe: 98.0%
Phosphorous, P: 0.040%
Silicon, Si: 0.280%
Sulfur, S: 0.050%
Physical properties
Physical properties
Density: 7.85g/cm3
Mechanical Properties
Tensile strength, Ultimate: 400-550Mpa
Tensile strength, Yield: 250Mpa
Modulus of elasticity: 200Gpa
Bulk modulus (typical for steel):140Gpa
Poisson ratio: 0.260
Shear modulus: 79.3Gpa
Advantages of mild steel
 Weldable: Unlike high-carbon steel, mild steel can be coalesced with far greater ease.
 Ductile: It is the measure of how much a material can be plastically deformed by
elongation, without fracture.
 Can be carburised: The major downside to mild steel is that it has a relatively low tensile
strength, meaning it‟ll break more easily under tension than other steels.
 Recyclable: No different than most metals, scrapped mild steel is vital in the production
of more of the same. Most steels can be recycled indefinitely without losing their quality,

21
 and due to its magnetic properties mild steel is particularly easy to recover from unsorted
waste.
 Cost effective: The least expensive of all steel types, many everyday objects are created
using mild steel, including auto-mobile chassis, motorcycle frames and a great deal of
cookware.

4.5.2 STAINLESS STEEL

Chemical composition
Iron, Fe: 42%
Nickel, Ni: 36%
Chromium, Cr: 19%
Manganese, Mn: 2%
Silicon, Si: 1.13%
Carbon, C: 0.080%
Phosphorous, P: 0.040%
Sulfur, S: 0.030%
Physical properties
Density: 8g/cm3
Mechanical properties
Tensile strength, Ultimate: 550Mpa
Tensile strength, yield: 260Mpa
Modulus of elasticity: 197Gpa
Poisson ratio: 0.27-0.30
Advantages of stainless steel

 Corrosion resistance: All stainless steels have a high resistance to corrosion. Low alloyed
grades resist corrosion in atmospheric conditions; highly alloyed grades can resist
corrosion in most acids, alkaline solutions, and chloride bearing environments, even at
elevated temperatures and pressures.

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  High and low temperature resistance: Some grades will resist scaling and maintain high
strength at very high temperatures, while others show exceptional toughness at cryogenic
temperatures.
 Ease of fabrication: The majority of stainless steels can be cut, welded, formed, machined
and fabricated readily.

Strength: The cold work hardening properties of many stainless steels can be

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4.6 OPERATIONS IN OUR PROJECT
 Drilling
 Facing
 Turning
 Boring
 Welding
 Grinding

Turning

Turning is the most important machining process and can produce a wide variety of parts.
Primarily, turning is used to produce parts cylindrical in shape by a single point cutting tool is
fed either linearly in the direction parallel or perpendicular to the axis of rotation of the work
piece, or along a specified path to produce complex rotational shapes. The primary motion of
cutting in turning is the rotation of the work piece, and the motion of cutting is the feed motion.
Different types of lathes are available today from general purpose to specific job oriented special
purpose machines. In general, turning refers general purpose to a class of processes carried out
on a lathe.

Figure 4.6.1

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Grinding
Grinding is the most popular form of abrasive machining. It involves an abrasive tools consisting
of grain of hard materials which are forced to rub against the work piece removing a very small
amount of material. Due to the random orientation of grains and some uncontrollable cutting
condition, the selection of proper parameters often becomes difficult. Grinding can be performed
to produce flat as well as cylindrical (both external and internal) surface efficiently. Grinding is
applied when the material is too hard to be machined economically or when tolerances required
are very tight.

Facing

Facing is the act of cutting a face, which is a planar surface, onto the work piece. Within this
broadest sense there are various specific types of facing, with the two most common being facing
in the course of turning and boring work (facing planes perpendicular to the rotating axis of the
work piece) and facing in the course of milling work (for example, face milling). Other types of
machining also cut faces (for example, planing, shaping, and grinding), although the term
"facing" may not always be employed there.

Figure 4.6.2

Boring

Boring is the process of enlarging a hole that has already been drilled (or cast) by means of
a single-point cutting tool (or of a boring head containing several such tools), such as in boring
a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter of

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a hole, and can be used to cut a tapered hole. Boring can be viewed as the internal-diameter
counterpart to turning, which cuts external diameters.

Welding

Welding is a fabrication or sculptural process that joins materials which are

usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature
metal-joining techniques such as brazing and soldering, which do not melt the base metal. In
addition to melting the base metal, a filler material is typically added to the joint to form a pool
of molten material (the weld pool) that cools to form a joint that is usually stronger than the base
material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.

Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit
is pressed against the work-piece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the work-piece, cutting off chips (swarf) from
the hole as it is drilled

Figure 4.6.3 Figure 4.6.4

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CHAPTER 5

RESULTS AND DISCUSSION

5.1 DISCUSSION
Two wheel drive off-road motorcycle concept is designed to make off-roading situations a lot
easier. While travelling using conventional motorcycle, it is difficult to travel through off-road
situations, broken roads and muddy roads because to loss of traction. In order avoid these
situations; the use of front wheel drive will help in these situations to a great extent.

Conventional motorcycles are not able to travel through slippery or difficult conditions because
of loss of traction or if they are unable to transmit power to the ground, this can be avoided by
powering the front wheel as well. This will be especially useful for people in rural areas where
there are no roads.

ADVANTAGES

 Off-roading capability will be increased to a great extent.

 The motor can be used as a stand-alone source of power to run the motorcycle in
emergency situations.

 Reverse motion can be achieved by using the electric motor.

 In two-wheel drive mode, the motorcycle will be able to climb steep hills and traction
less terrain with ease.

 Servicing of motor and its maintenance can be done easy, when compared to
conventional IC engines.

 Electric motors are a lot more efficient.

 The motorcycle will be able to accelerate faster from a stand still because of the torque
offered by the electric motor.

 It will help in better weight distribution & gives better handling to the vehicle in some
cases.

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DISADVANTAGES

 The addition of an electric motor system will make the motorcycle more complicated.

 The overall weight of the motorcycle will be increased.

 Adding this system will be an expensive affair in some cases.

 The wear on the front tire will be significantly increased because it is powered.

 Steering the bike will be heavier because of the added weight at the front.

 The load on the engine will be higher because of the extra power required to charge the
battery and run the motor.

5.2 RESULT

The project was successfully completed and we were able to use the motorcycle on off-road
conditions. The system worked as expected both on road and off road. We were able to attain the
theoretical top speed with the motor working as a standalone power source. The motor selected
had the same output as the engine, thus both the wheels will have the same amout of torque
available when required.

The fabricated mounts could easily handle the stress and shocks inflicted when the motorcycle is
running. The batteries were connected in series to obtain the required output. The batteries were
able to power the motor and controller adequately

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CHAPTER 6

SUMMARY AND CONCLUSIONS

6.1 CONCLUSIONS

In an ordinary motorcycle, the power only goes to the rear wheel. Thus when the motorcycle
goes over slippery surfaces or encounters big obstacles, the rear wheel might slip and cause a
crash. When we power the front wheel along with the rear wheel, the grip offered by both the
wheels will help in these situations to a great extent. This project will particularly help riders
who go off tarmac quite often, especially in rural areas where roads are not common. With both
the wheels powered, there will be plenty of torque available to go off-road and avoid tricky
situations. The location of motor and the motor mounts will vary with different motorcycles. The
output of the motor is selected based on the power and torque output of the engine.

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CHAPTER 7

REFERENCES

 Theory Of Machines By Rattan.S.S

 Kinematics And Dynamics Of machinery By Wilson.C.E
 Wikipedia
 Design and Data Handbook For Mechanical Engineers By K.Mahadevan
 Electrical Technology By Theraja.B.L

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