60kmph
46
Type of tyre
24
ATV 24X 8
TUBINGS
NORMALISED
STEEL
WALL
THICKNESS
0.76
COCKPIT
DIMENSIONS
38X 32.23
LENGTH
92
HEIGHT
42
WIDTH
64
TRACK WIDTH
58
WHEEL BASE
68
GROUND
CLEARENCE
7.47
NO. OF WELDS
45
WELD LENGTH
1.91(for one
joint )
TUBE(OD)
Material
AISI 4130
NORMALISED
STEEL
STEEL
DENSITY
7.85gm/cc
YIELD
STRENGTH
460MPa
TENSILE
STRENGTH
560MPa
POISSONS
RATIO
0.285
Front Analysis
Rear
Analysis
Side Analysis
SUSPENSIO
N
LINKAGE DESIGN
Center of
gravity
height
Ground
clearance
Roll
center
Motion
ratios
10.07'
7.47
At ground
0.5
SUSPENSION GEOMETRY
Camber
(Negativ
e)
0.5
Caste
r
KPI
Scrub
radius
4
0
0
DESIGN OF DAMPER
Design of spring
Parameters Front
Rear
Suspensi Suspensio
on
n
Wire
diameter
8.6 mm
8.6 mm
Inner coil
diameter
51.6 mm
51.6 mm
Outer coil
diameter
60.2 mm
60.2mm
Toe
in
Toe
out
Total
number
of turns
36
35
Free length
of strut
423.15
mm
403.23m
m
Parameters
FRONT
SUSPENSIO
N
REAR
SUSPENSION
Pitch of
suspension
spring
12.09m
m
11.85mm
DAMPING
RATIO
0.5
0.5
50.56m
m
44.42mm
STIFFNESS
Eye-to-eye
length of
strut
(unloaded)
RIDE
1.135Hz
Max.
101.12
88.9 mm
1.23 Hz
BRAKE SYSTEM
Components
selection
Type of brake
Master cylinder
Brake circuit
Caliper and Disc
Calculations
Values
784 N
Force on Caliper
1747.2 N
Braking Torque
188.6 N-m
Stopping distance
7.06m at 40 kmph
Stopping time
1.27 s (from 40 to 0
kmph)
Deceleration
8.73 m/s2
Weight Transfer
557 N
Specifications Values
Disc diameter
Outer/inner
220 mm/160mm
38.1 mm
Master cylinder
diameter
25 mm
Pedal ratio
4:1
Brake Disc of
STEERING
SYSTEM
COMPONENT
Measurement
Wheel base
68
Wheel track
58
Inner steering
angle
40
Outer steering
angle
26.12
Length of tie-rod
39.90
Steering ratio
12:1
Turning circle
radius
2.79 m
Rack travel
4.25(lock to
lock)
Pinion turn
Component
measurement
Ackermanns %
85.54
IBJ centre
distance
14
OBJ centre
distance
36.359
Steering
No power assist
Steering wheel
diameter
12.59
Steering torque
64 N-m
POWER TRAIN
Specifications
Values
Power
10 HP
Max torque
23.8 N-m@2500
rpm
Max speed
16.66 m/s
Tyre size
24
Transmission
efficiency
0.8
GEAR
TRACTI ROLLING
VE
RESISTAN
FORCE CE (N)
(N)
1ST
5.735
2ND
3.0407
3RD
11.40 10
2.077
271.32 775.2
48.8
Max.AC
CELERA
TION
(m/S2)
Bill of Materials
Chart Title
COMPONENT
CHASSIS
77
268/m
sprung
ENGINE
26.76
50,000
sprung
GEAR BOX
36-40
15,000
sprung
GEAR LEVER
0.05-0.08
300
sprung
CLUTCH
1.72
1250
sprung
SUSPENSION
SYSTEM KIT
23.6
65000
sprung
BRAKE PADS
0.15-0.25
600
unsprung
BRAKE CALIPER
1.8-2.2
1500
unsprung
BRAKE FLUID(ml)
355
509
unsprung
250
unsprung
16.36
20,000
unsprung
16.36
20,000
unsprung
16.36
20,000
unsprung
16.36
20,000
unsprung
6,000
sprung
10
11
12
13
14
15
MASS(KG) COST(INR)
SPRUNG/UNSPRU
NG
S.NO.
GANTT CHART
No COMPONEN
T
1
Frame
FAILURE MODE
Engine
Engine damage
Transmissio
n
Steering
system
Structural failure
5.
Knuckles
Mechanical
failure
Breakage,
mechanical
failure.
Breakage failure
6.
Braking
System
Mechanical
failure
7.
Tyres, rims
Mechanical
failure
8.
Driver seat
9.
Electrical
Structural failure
affecting safety
Electrical failure
4.
DFME
FAILURE CAUSE
A
FAILURE EFFECT
PREVENTIVE
ACTIONS
Due to excess
Overall Damage
Choose material
load.
to roll cage.
with high factor of
safety(FOS).
Unavailability clean engine failure and additional safety to
air and proper fuel
risk to drivers life driver
Fatigue/ cyclic
inoperable
Suitable
loading
Transmission system
Excess load applied Steering failure;
Verification of
by driver.
Safety of driver.
desired specification
and testing
Failure due to
Damage to
Choose material
bending, crushing
suspension
with high FOS.
stress
system .
Not sufficient
Damage to
Choose material
braking force
vehicle in
with high FOS and
undesired
careful testing
circumstances
should be done
damage by foreign Inability to
Verification of proper
debris
operate vehicle
specification and
testing
Excess load leading Endangers
Proper fitting should
to bearing stress
drivers safety
be done
Water
drivers safety
Proper insulation
Workshop Facilities
TEAM STRATEGY -
7.Lathe Machine
8.Universal testing machine
1.CHASSIS DESIGN
2.TRANSMISSION
3.SUSPENSION
4.BRAKES
5.STEERING
6.SAFETY & ERGONOMICS
7.ELECTRIAL CABLES