SAE/BAJA/mBAJA/Team/WOLF/2023-24

UNIVERSITY INSTITUTE OF ENGINEERING & TECHNOLOGY

(A Constituent Autonomous Institute)
KURUK SHETRA UNIVERSITY, KURUK SHETRA-136119 (HARYA NA )
(Established by the State Legislature Act XII of 1956)
'A' Grade, NAAC Accredited)

PROJECT REPORT
ON
All Terrain Vehicle 4X4

Under the guidance of:

Dr. VISHAL AHLAWAT
Assistant Professor
Mechanical Deptt, UIET KUK

Submitted By:

ALOK KUMAR 252004015 ASTITAV 252004003

PANKAJ 252004023 FAHAD SAIFI 252004013
AMAN 252004025 DEEPAK 252004016
SAHIL TANWAR 252004026 MOHIT 252004024
ARUNESH KASHYAP 252004066 KULSHRESTH 252004027

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INDEX
S.NO TOPIC PAGE NO

1 Acknowledgement 3

2 Abstract 4

3 Introduction 5

4 Overall Vehicle Specification 6

5 Roll Cage 7

6 Brake system 8

7 Steering system 10

8 Power train 12

9 Suspension system 13

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ACKNOWNLEDGMENT
We would like to express our gratitude and appreciation to all those who gave
us the possibility to complete this project. Special thanks to our mentor
Dr.VISHAL AHLAWAT, whose help, suggestions and encouragement
helped us in all the time of designing process, fabrication process and in writ-
ing this report. We also sincerely thanks for the time spent proofreading and
correcting our mistakes.

We would also like to acknowledge with much appreciation the crucial role of
the staff in Mechanical Laboratory, who gave us a permission to use lab equip-
ment and also the machine and to design the drawing and giving a permission
to use all the necessary tools in the laboratory.

Many thanks go to all the Lecturer and supervisors who have given their full
efforts in guiding the team in achieving the goal as well as their encouragement
to maintain our progress in track. My profound thank goes to all our class-
mates, especially to all our friends for spending their time in helping and giv-
ing support whenever we need it in fabricating our project.

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ABSTRACT
ATV is a vehicle that can move on almost all type of terrain and travels on low
pressure tires. Society of automotive engineers (SAE), India organizes an ATV
designing event for engineering undergraduates known as BAJA. SAE-BAJA
event involves designing, fabrication and validation of a single seater four wheeled
all-terrain vehicle which takes part in a series of off-roading events which tests its
manoeuvrability, acceleration, durability, gradeability and braking characteristics.

Methods to achieve our project is to work on different components of our vehicle

in a specific team such as Brakes, Suspension, Steering, Power-train, Roll cage
/chassis

Chassis is an important part of the BAJA vehicle that supports body and other
different parts of the vehicle. It also surrounds and protects the occupant in case
of impact and roll over incidents and also gives the aesthetics of the vehicle. The
paper deals with selection of material and cross section for the chassis and analyse
the frame design for different loading conditions to predict whether it will survive
various impact scenarios using ANSYS workbench. The chassis design will be
based on BAJA SAE India 2024 rule book taking safety and other aspects into
account. The results from these simulations indicate that the frame is safe enough
for the variety of worst-case scenarios tested.

In ATV, we have to use various braking component in the system and design a
effective braking system considering various scenarios of the event.

The steering system has the primary function of manoeuvring the vehicle in the
desired direction. Also, the steering system was tested under different geographical
terrains. The different software such as were used to ensure precise dimensions &
accurate results. The Rack & pinion gears were designed. Theoretical values were
validated with the help of ‘Lotus Shark’ software. The designed system was mod-
elled using CAD software. Structural analysis was done to check whether the de-
signed components will sustain critical loads.

The suspension and steering systems of the SAE Baja vehicle needs to be adap-
tive, durable, efficient, and relatively inexpensive. The vehicle must be able to
withstand the harsh environment of off-road competition and recreational driving.
The vehicle needs to traverse over large rocks, downed logs, mud holes, steep
inclines, jumps, and off camber turns. In order to meet the demands of the race
course, the steering and suspension systems were designed and redesigned for a
more effective turning radii and efficient use of suspension travel.

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INTRODUCTION
ATV(All-terrain vehicle) is the four-wheeled motorized vehicles with an overall
width of 56inches according to the rulebook provided by SAE.
These vehicles are the off-roading vehicles designed in such a way that our
driver will be safe in driving the vehicle.
We are considering the overall weight of vehicle 300kg and using AISI4130 ma-
terial pipes with OD-29.4mm and OD-25.4mm as primary and secondary mem-
bers in the Roll Cage having thickness of 1.65mm in our vehicle.
The other specifications we have considered about our vehicle are as follow:-

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Overall Vehicle Specifications

Total Weight 300 kg

Driver Weight 70kg

Sprung Mass 220kg
Unsprung Mass 80kg
Track Width 56 inch
Wheel Base 60 inch
Ground Clearance 351mm
Kerb Weight 230 kg

Front Suspension Double Wishbone

Rear Suspension H-Arm with Axle with Camber

link
Front/Rear Brake Outboard Disk
Steering Rack and Pinion
Tire and Rims (Front/Rear) 23*7-10 10*5(3+2) / 23*7-10
10*5(3+2
Maximum Speed 55km/h

There are four department in our group.

1. Rollcage
2. Brake system
3. Steering system
4. Power train
5. Suspension system

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ROLLCAGE
DESIGN PROCESS CHART
1. Hard point from VD
2. Verifying the packaging of all components
3. Cockpit Design considering Driver Ergonomics
4. Structural Analysis
5. Final check
CAE (Computer-aided engineering)
1. Geometry clean- up
2. Meshing
3. Element quality check
4. Setting up Loads
5. Analysis Run

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BRAKE SYSTEM
Braking system is designed to be capable of locking all four wheels with minimum
stopping distance, to control vehicle speed and to keep the vehicle stationary when it
located on a slope.
Our aim will be to design a braking system which is easy to operate and light in
weight.

PARTS OF BRAKING SYSTEM

1. BRAKE CALLIPERS:
Its assembly comprises brake pads and pistons. We are using floating caliper to fa-
vour better heat dissipation and minimize chances of brake fading. Floating calipers
carries piston on only on inboard side of rotor and the entire caliper must shift inward
for outer pad to contact the rotor.
Calliper Bore: 25.4mm
2. BRAKE LINE:
Brake lines are thin, flexible tubes that transfer fluid pressure from master cylinder to
the brake callipers. We are using X- split circuit in which each output from the Tan-
dem master cylinder supplies one front brake and its diagonally opposite rear brake ,
so that in the event of either line failing one- half of the normal maximum braking still
remains available from one front and one rear wheel.

Fig. 01: Brake Layout

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3. BRAKE ROTORS:
Rotor is the metal disc attached to the hub of the wheel. Rotors are significant parts
in applying the braking torque to the wheel. Disc brakes provides better heat dissipa-
tion,
Disc Type: Outboard Disc
4. MASTER CYLINDER:
It converts the pressure on the brake pedal to hydraulic pressure by feeding brake fluid
into the brake circuit and controlling according to the mechanical force.
We will use the TMC which have separate fluid reservoirs to prevent braking system
of our vehicle.
In case if one brake line broke or do not work then we should have atleast 50%effi-
ciency of braking system.

We are using Tandem Master Cylinder(TMC) of Maruti800(Bosch) with bore size

19.04mm.

Fig. 02: Tandem Master Cylinder (TMC)

PARAMETER VALUE
Height of center of gravity 531mm
Pedal ratio 6:1
Disc size 200mm (O.D), 160mm (I.D)
Caliper bore 25.4mm
Coefficient of friction between road and 0.65
Tyre
Required torque 184.172 N-m(F) 153.221 N-m(R)

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STEERING SYSTEM
PURPOSE OF STEERING SYSTEM:

The Steering system allows the driver to guide the car along the road and turn left or
right as desired.
THE SYSTEM INCLUDES THE FOLLOWING:
1)Steering Wheel … which driver controls
2)Steering Gear … converts rotatory motion into straight line
3)Steering Gear … transmit steering gear movement to the front wheels
The steering system configuration depends on vehicle design.

FUNCTIONS:

1) Achieve angular motion of the front wheels.

2) Directional Stability
3) Facilitate straight ahead recovery after turn
4) Minimize wear and tear
5) Absorb road shocks
6) Provide perfect rolling motion

Fig. 03: Steering Layout

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OBJECTIVE

• Shorter turning radius .

• Optimizing Steering effort according to driver’s comfort
• Low Speed Maneuverability

STEERING SYSTEM

System Ackermann
Mechanism Rack and Pinion
Rack and Pinion material EN353
Steer Tendency Over Steer
Ackermann% 38.425%
Steering Angle (in) 40 deg
Steering angle (out) 25.02deg
Turning Circle Radius 2370.92mm

Steering ratio 4:1

Rack Travel 85.66mm

Tie Rod Length 598.85mm

Fig. 04: Rack and Pinion

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POWER TRAIN
The mechanism by which power is transmitted from an engine to the axle in a Vehicle
is Transmission. Transmission is very important system to run vehicles.
Transmission consists of Engine - CVT - Gearbox - axle Shaft - Wheels. CVT and
Gearbox combinedly gives the power reduction ratios of engine to get the required
amount of speed and torque.
CVT means “Continuous Variable Transmission”, it gives the variable amount of re-
duction ratio in between 0.4 to 3.9 which reduces the engine speed. CVT has fixed ra-
tios as it can't be changed in standard CVT Therefore, Gearbox plays an important
role in the transmission.
The main objective of this study is to design and analyse the gear box for all-terrain
vehicles.

METHODOLOGY
Gearbox has been designed in such a way that weight of the gearbox should be re-
duced, gears tooth does not go under failure. And hence to get the accurate gear ratio,
to fulfil all the requirements, the Reverse engineering method is adopted to design the
2-stage gearbox. This method is very effective as we already know our requirements.

First, we calculate maximum load for our design by which our design will not go un-
der failure.
The approach is in the following ways: Calculation of Gear Ratios → Design of Gears
→ Calculation of Loads acting on the gears → Gear Materials Selection → Analysis
of gears → Calculation of factors depends upon the gears.

ENGINE SPECIFICATION:
Briggs and Stratton 10 HP OHV Vanguard Model 19
Displacement: 305 cc
Max power: 7.35 kW @3800
Max Torque: 19.6 Nm @2800

POWERTRAIN LAYOUT

GEAR MATERIALS SELECTIONS

Material EN353
Tensile Strength 680 MPa
Yield Strength 440 Mpa
Poisson’s Ratio 0.26

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SUSPENSION SYSTEM
The vehicle suspension system is responsible for driving comfort and safety as the
suspension caries the vehicle body and transmits all forces between the body and the
road. Semi-active or active components are added to have a good impact on these
qualities. These make it possible for the suspension system to adjust to different driv-
ing scenarios.
Driving comfort and safety are significantly increased when a variable spring is added
compared to suspension systems with fixed features.
For this method to work, it is necessary to understand both the control behaviour of
these components and the laws governing how to modify the free parameters in re-
sponse to driving excitations. This necessitates a mechatronic design that includes the
identification and fault detection of the related components.

Design of compression spring for suspension system

Design of helical compression spring involves following

1. Should possess sufficient strength to withstand the external load.
2. Should have required load-deflection characteristics.
3. Should not buckle under external load.
4. Should insure comfortable ride.
5. Should provide elastic connection between load carrying systems and the axles.
6. Should damp their vibration
7. Should perform with desired economy
8. Should fit into given space and operate accordingly

Objective
• Improve stability.
• Reducing roll over tendency during corner
• Softer suspension, increased wheel travel

Suspension Type
• Front – double wishbone damper to lower
• Rear-H-frame lower

Fig. 05: Double wishbone Fig. 06: H-frame lower

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