Optimized Design and Analysis of Chassis of A Quad Bike

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation........
Volume 4, Issue 5, May 2016
Optimized Design and Analysis of

Chassis of a Quad bike
S.A. Puviyarasu1, V.S. Ukkeshwar2
1
S.A. Puviyarasu, Dept. of Mechanical Engineering, Dr N.G.P Institute of Technology
V.S. Ukkeshwar, Dept. of Mechanical Engineering, Adithya Institute of Technology
ABSTRACT
The epicentre goal of this study is to optimize design and analysis a quad bike chassis. This is an ATV based platform that
comprises of various automotive components like chassis for which more durable design is a primary requirement as these
vehicles are more concentrated on rider safety parameters and all other requirements. In order to accomplish this task, various
tests like front impact, rear impact, side impact tests were made with the aid of theoretical calculations. The design of chassis
of the vehicle using PTC CREO 2.0 software and analysis is carried out using ANSYS software.
Keywords: Quad bike, chassis, FEA etc
1. INTRODUCTION
As the name implies, Quad bike is also known as a quadric cycle, four wheeler bike. It is designed to handle a wider
variety of terrain than most other vehicles.
The main objective of this study is to optimize design and develop a chassis of a quad bike. The chassis is the main
component in charge of supporting vehicles subsystems and taking care of the driver safety at all time. The chassis
design needs to be prepared for impacts created in any certain crash or rollover. It must be strong and durable taking
always into account the weight distribution for a better performance [1]. In order to accomplish this task, there is a
wide variety of methodology is used to enhance the safety of the quad bike. For chassis various loading test like front
impact, rear impact, side impact are carried out. The design process of this single-person vehicle is iterative and based
on several engineering process. The material used for the frame is AISI 1020 because of good weld ability and strength
for the manufacturing process. The design of chassis of the vehicle using PTC CREO 2.0 software and analysis is
carried out using ANSYS software.
Figure 1: Quad bike
2. MATERIAL SELECTION
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 carbon steel. we
choose the material AISI 1020 with 0.12 to 2% of carbon is used in the frame design because of its good weld ability
relatively soft and strengthens as well as good manufacturability. A good strength material is important in a roll cage
because the roll cage needs to absorb as much energy as possible to prevent the roll cage material from fracturing at the
time of high impact. This AISI 1020 STEEL gains hardness and strength with heat treatment. This carbon steel is a
commonly used plain carbon steel. It has a good combination of strength and ductility [2]. Then it is also assured by
analysis in Creo software. The various Physical properties of the material are follows
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ISSN 2321-6441
Table 1: Material properties of mild steel

S.NO
PROPERTIES
VALUES
1)
Density
7.87 g/cm3
2)
Tensile strength
420 Mpa
3)
Yield strength
350 Mpa
4)
Modulus of elasticity
205 Mpa
5)
Shear modulus
80 Gpa
6)
Poissons ratio
0.29
7)
Elongation at break
15%
The chemical composition of the material isManganese, Mn

= 0.30 - 0.60%
Carbon, C
= 0.18 0.23%
Sulfur, S
= 0.05% (max)
Phosphorous, P
= 0.04% (max)
Iron, Fe
= 99.08-99.53%
The above mentioned properties satisfy the technical requirement of material which is to be used in frame.
3. DESIGN APPROACH
FRAME
The frame is the component for carrying the engine and body of the vehicle. It is a structural member is used to carry
all sub- assembly components of the vehicle the main objective of this design is durable, strong, weight reduction,
weight distribution to better performance of the vehicle [3]. The double cradle frame which gives high strength and
load carrying capacity.
Figure 2: 3-D model of frame
Figure 3: 3-D top view
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FINITE ELEMENT ANALYSIS (FEA)
Finite element is a method for solving the approximate solution of physical problems involving complicated geometry,
loading, material properties and partial differential equations such as: Solution of elasticity problems, Determine
displacement, stress and strain fields, and transient dynamic, steady state dynamic and maximum deformation i.e.
subject to sinusoidal loading, modes and frequencies of vibration, modes and loads of buckling. The frame is analyzed
at much higher forces than in real case scenario [4].
Loading analysis
The loading analysis of the chassis is carried out. It withstands of more than 6g impact forces. When the worst case
scenario of the vehicle, the chassis can withstand much stability of higher forces and gives safety to the human body
and vehicle. It is assumed that worst case collision will be seen when the vehicle runs as stationary object [5].
Table 2: Units used in modeling analysis

Metric (m, kg, N, s, V, A)
Degrees rad/s Celsius
Angle Degrees
Rotational
rad/s
Velocity
Temperature Celsius
Unit System
STATIC ANALYSIS
Frontal impact
Rear impact
Side impact
Table 3: Model Geometry of Chassis
Object Name Geometry
State Fully Defined
Definition
C:\Users\Student\Desktop\frame\frames.IG
Source
S
Type Iges
Length Unit Meters
Element
Program Controlled
Control
Display Style Part Color
Bounding Box
Length X
Length Y
Length Z
Properties
Volume
Mass
Statistics
Bodies
Active Bodies
Nodes
Elements
Mesh
1.495 m
0.45851 m
0.42613 m
3.1493e-003 m
24.879 kg
29
29
52452
20695
None
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ISSN 2321-6441
1. FRONTAL IMPACT
The mass of the vehicle is 280 kg (assumed). Generally in the case of pure elastic collision in frontal impact the linear
velocity remains at 60Kmph. The collision is assumed to be perfectly plastic.
Figure 4 Equivalent stress analyses of chassis (front)
Figure 5 Total deformation of chassis (front)
2. REAR IMPACT
Figure 6 Equivalent stress analysis of chassis(rear)
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ISSN 2321-6441
Figure 7 Total deformation of chassis (rear)
3. SIDE IMPACT
Figure 8 Equivalent stress analysis of chassis (side)
Figure 9 Total deformation of chassis (side)
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Figure 10 Factors of safety
RESULTS
CASE
Forces
FRONT
REAR
SIDE
IMPACT
IMPACT
IMPACT
6g
4g
4g
Maximum
deformation
8.3199e-5 m
0.0011108 m
4.556e-5 m
Equivalent
0.0001684
m/m
0.00078016
m/m
8.3817e-5
m/m
Equivalent
von-misses
stress
3.368e7 Pa
1.5603e8 Pa
1.6763e7 Pa
Max. shear
elastic strain
0.0002474
m/m
0.001111 m/m
0.00012379
m/m
Max. shear
stress
1.9179e7 Pa
8.6124e7 Pa
9.5965e6 Pa
Max. principal
elastic strain
0.00012093
m/m
0.00032851
m/m
6.7988e-5
m/m
Max. principal
stress
2.065e7 Pa
6.0432e7 Pa
1.3691e7 Pa
Safety factor
10.43
10
15
Elastic strain
CONCLUSION
The objective of designing and analysis a quad bike chassis is with high safety, low weight, high stability, and strength.
The Structural Analysis of Chassis shows that the maximum equivalent stress is less than the Yield Strength of the
1020 Mild Steel. The distributions of the stress that acting on the chassis and critical area that will lead to failure are
also observed. The design process included using PTC CREO and ANSYS software packages to model, simulate, and
assist in accelerating design.
REFERENCE
[1]. Pre manufacturing of quad bike Volume 5, Issue 6, June (2014), pp. 68-76
[2]. Design of machine element book by Chand
[3]. Roll cage of ATV IOSR (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 49-53
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ISSN 2321-6441
[4]. Designing of ATV, Ijsrp, Volume 4, Issue 12, December 2014 1 ISSN 2250-3153
[5]. PSG design data book
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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation........

Volume 4, Issue 5, May 2016