Design of bi ratio steering geometry for ATV front steering

AMZ AUTOMOTIVES

A summer training report

Submitted in partial fulfillment of the requirements for the award of degree of

SUMMER INTERNSHIP ON ATV

Submitted to

AMZ AUTOMOTIVES

From 05/04/20 to 06/04/20

SUBMITTED BY

Astha Kiran Submitted to:

1901106605 industrial expert mr RAHUL RANJAN

astha kiran (senior research associate)

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 PREFACE

As a part of engineering curriculum we are required to do internships and make report about the
topic"ATV designing and formula" we have learnt during our internship program.
The objective behind this project report is gain knowledge about designing atv and learn about various
mechanical tools

In this project report we have included about different parts required to make a vehicle their uses
advantages and disadvantages. It also helps us to enhance our knowledge in the field of making or
designing a vehicle.

Through this process we came to know about importance of team work and togetherness. We undergo
many experiences during this period and learned many new things which would be helpful in our future

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 Certificate

This is to certify that I Astha Kiran of college of engineering and technology Bhubaneswar has successfully
completed the project report on the given topic “ bi ratio steering geometry of front wheel of atv”.

I assure you that this project is originally made by me without copying from any one directly. The pictures are taken
from the internet to make this project more informative and interesting.

Astha Kiran

Signature of candidate

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 INDEX

Serial Heading
no.

1 Declaration

2 Certification

3 Chapter-1 INTRODUCTION OF THE COMPANY

4 Chapter 2: introduction to automobile and vehicle dynamics

5 Chapter 3 :- Fundamentals of chassis

6 Chapter 4 :- Steering geometry ratio

7 CHAPTER – 5 CONCLUSION

8 Bibliography

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 CHAPTER 1- INTRODUCTION TO COMPANY

Automotive comprises automobiles and auto component. It has witnessed a continuous evolution ever
since the development of first few prototype AMZ group are pioneers involved in manufacture of AMZ
motor vehicles and self driven automobiles including most component. They have polish origin , besides
production they give emphasis to deliver the knowledge of design and manufacturing and self driving
autonomous vehicles to the young energetic professional learner pursuing studies in mechanical and
automobile sectors pioneer automobile manufacturer not only had to solve the technical problem and
impart of theoretical knowledge but also have to make aware of basic decision about what to produce what
ought to be actually enjoyed with greatest acceptance. It throws the knowledge about the limitation
imposed in automotive which will provide technological advancement with mass production and a process
of combining precision, standardization ,interchangeability , synchronization and innovation.

AMZ Automotive is a pioneer in the field of providing practicality to the theoretical knowledge acquired
by the engineers in the field of Mechanical, Aerospace, and Automobile. It offer workshops to the
students to implement the knowledge obtained by them in the real world situations. It extract them out of
the nutshell and let them face the real world problems under the guidance of our phenomenal faculty
members like, former F1 Marshall, Research Engineers, Rally Car Designers and Rally drivers who have
years of experience in the field of Automobile and Mechanical Engineering. It promote interactive and
complete hands-on training in the ATV, Go-Kart and Formula prototype vehicles. It have evolved over the
time and have taken a comprehensive approach to the latest studies. It have a well-formulated workshop
that includes academic

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lectures on dynamics, CAD design, design analysis, fabrication, and testing. It organize participating
workshops in different colleges and provide specially designs workshops to benefit the students and help
them with all-round development. It focus on polishing not only their engineering skills but also in
enhancing their team management and leadership skills.

The AMZ located at AM tower 07 teachers colony Ajmer road Jaipur Rajasthan. AMZ automotive has
emphasized the knowledge intricacies behind the designing and fabrication of ATV vehicles.ATV
designing, manufacturing and self driving autonomous moving vehicles making was taught from scotches
to an industrial assembly line which includes cutting, bending, welding, grinding of chassis members ,
engine mounting, wheel assembly, steering , suspension component manufacturing of braking system,
installation of tyre pressure calibration within a given parameters .The AMZ had taught us the stress
analysis of each component while teaching the designing. The design of the vehicles are in CAD software
mostly in 2D and 3D sketching. Over all the teaching is worth considering. It acknowledge the best out of
it.

It includes many courses which extends the knowledge of students in automobile sector. The course I
opted for was atv designing and development. It helped me to enhance my knowledge in designing of
ATV vehicles. According to this following chapter were covered in each day-

21 DAYS TRAINING PROGRAM ON ATV DESIGNING AND DEVELOPMENT-

Statics of automobile engineering – 1 Day

Dynamic balancing – 2 Days
Designing of automotive components – 2 Days
Practical session for hand on experience – 2 Days
Automotive development – 6 Days
Final vehicle assembly – 1 day
Automotive testing & tuning – 1 day

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1) Static: In this part we will be discussing static parts of automobile that how each and every component
works,

– Fundamentals of chassis design

– Suspension system
– Braking system
– Steering system
– Engine working and fundamentals
– Working and explanation of latest technologies like CRDI engine and many more

2) Dynamics: In this part we will be discussing dynamics of automobile in deep

and discuss how to balance all the components of a car,

– Steering dynamics
– Braking performance triangles
– Chassis designing parameters
– Derivation of drifting equation and turning equation
– Designing parameters for suspension designing
– F.E.A
– Engine valve timing diagram and engine designing parameters

3) Designing: This will be the implementation of the things that we will learn in above two parts,

– Ergonomics considerations in designing a car

– Ride & handling consideration in design
– Suspension lift point designing
– Chassis designing and stress analysis of each component – Basic as well as complex surface generation
– Decaling and rendering of a vehicle
– Fixtures generation
– Sub-component assembly
– B.O.M (Bill of material)
– Designing of tire and rim

4) Fabrication:
In this part, we will be manufacturing the ATV from very scratch which all includes,

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– Roll cage profile generation
– Development of roll cage fixtures
– Roll cage welding and weld check confirmation
– Roll cage suspension hard point adjustments
– Attachment of sub-components holder
– Engine mounting and it’s tuning
– Coupling of engine & transmission
– Brake bleeding and installation of braking, steering assembly
– Final vehicle assembly with all subcomponents
– Electrical wiring, safety consideration & attachments
– Wheel assembly of the front and rear drive vehicles, tire pressure calibration, cornering ability test.
– Tuning & test run of ATV by all the students

Day wise description

Day 1 Topics:

Introduction to “Automobile Engineering”

• Difference b/w super, ATV, sports, formula car Chassis
• Goals of chassis
• Types of chassis: a) Monocoque b) Ladder-frame c) Space-frame d) Backbone chassis
• Types of cars based on that
• Rigidity and uses of different types of chassis
• Suspension system for on road and off road applications
• Types of suspension springs
• Uses and applications of each
• Concept of all terms related to suspension designing (camber / caster / kingpin inclination / toe angle /
bump rebound / spring rate / camber thrust / jacking forces)
• Types of dampers and application
• Suspension mechanisms
• Scrub radius
• Tire mechanism
• Tire nomenclature

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Day 2 Topics:

Steering mechanism
• Types of steering mechanism
• Co-ordinate system for mechanism
• Euler angles
• Turning radius
• Cornering stiffness
• Slip angle
• Steering ratio
• Derivation of turning equation
• Concept of understeer and over steer
• Concept of drifting
• Suspension designing and
• balancing parameters
• Jacobian matrix application in automotive dynamics
• F.E.A Anti-dive and anti-squat geometry
• Balancing of double wishbone suspension for off-road and on-road application Spring rate and dynamic
camber calculation
• Camber change rate
• Front view swing arm & side view swing arm length calculation
• Braking mechanism
• Braking dynamics
• Braking performance triangles
• Designing parameters for disc brakes

Day 3 Topics:

Basic working of I.C. engine, types and categorization

• Components of an I.C. engine
• Valve timing diagram and its optimization for performance as well as economy
• Dynamics of I.C. engine
• Tuning parameters of a spark ignition four-stroke fuel injector single cylinder engine
• Intake manifold roughness calculation and advantages
• Optimization of volumetric, combustion and thermal efficiency for a commercial vehicle engine

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Day 4 Topics:

Introduction to CAD
• Introduction to solid works tools and commands
• 3- d part modelling
• Designing of sub-assemblies of an automobile

Day 5 Topics:

Introduction to “Automobile engineering”

• Assembly feature in CAD

• Assembly of subcomponents on frame
• F.E.A Stress analysis on chassis, frame and different subassembly of vehicle

Day 6 Topics:

Introduction to office products like decaling and rendering

• Body surface designing
• Complex body works designing
• Optimization of designs made by participants

Day 7 Topics:

Assembly of all sub-components in the chassis, offices products – rendering, decaling. Sketching of
different chassis members on sheet

Day 8 Topics:

Fixtures preparation, Bending and profiling of chassis members

Day 9 Topics:

Fabrication of drivers cockpit, front suspension box,

Day 10 Topics

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Fabrication of engine & transmission compartment

Day 11 Topics:

Fabrication of front suspension wishbones and rear suspensions

Day 12 Topics:

Fabrication of steering and braking subcomponents

Day 13 Topics:

Assembly of all components

Day 14 Topics:

Wiring harness and vehicle control installation

Day 15 Topics:

After complete fabrication, participants will do rigorous testing of the ATV and will optimize its
performance.
Certification

All the participants will be given “Certificate of Participation” issued by AMZ AUTOMOTIVE.

Requirements from college

Seminar Hall with a capacity of 200 students

• Projector system and mike system facility
• Accommodation facility for the faculty

Further Amz provide brief information about how electric car are made. It enlarge our theoretical
knowledge and increase our understanding by providing practical on it

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Chapter 2: introduction to automobile and vehicle dynamics

 Static part
 Dynamic part
 Practical

Basis of automobile engineering:-

 Automotive
 Automobile
 Automation

Automotive:- any machine with a moving part.

Automobile:- any machine with a moving part which helps in locomotion.

Automation:- any machine with a moving part which repeats itself after an interval.

Types of cars:-

 Sports car- It is designed to emphasize handling performance and thrill of driving.

 Formula 1 car- it’s a racing car used in the race .
 Super car- these re exotic car with a very high performance.

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 Concept car- a concept vehicle showcase in different events or functions, designed by engineers
which company want to launch in future after collecting the reviews from consumers.

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Pic 2.1:-sports car

Pic 2.2 :- formula car

Pic 2.3:- super car

Pic 2.4:- concept car

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 Fundamental of chassis
Chassis :- Fully functional part of vehicle where all the sub assemblies are installed on it which
make the body movable from one place to another place.
Types of chassis
 Backbone chassis
 Ladder frame
 Tubular space frame
 Monocoque
 ULSAB

Backbone chassis :- it is a very simple, strong tubular backbone ( usually in rectangular section)
connects the front and rear axle and provides nearly all the mechanical strength. Inside which there is a
space for drive shaft in case of front engine, rear wheel drive layout.

The whole drive train, engine and suspension are connected to both ends of backbone.

Picture 2.5:- backbone chassis

Ladder frame chassis:- it’s construction indicated by it’s name, looks like a ladder- two longitudinal rails
interconnected by several lateral and cross braces. The longitude members are the main stress member.
They deal with the load and also the longitudinal forces caused by acceleration and braking. The lateral
and cross members provide resistance to lateral forces and further increase torsion rigidity.

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 Pic 2.6 :- ladder frame chassis

Tubular space frame :- it employs dozens of circular section tubes(some may use square section tubes for
easier connection to the body panels, through circular section provides the maximum strength), position in
different directions to provide mechanical strength against forces from anywhere. These tubes are welded
together and forms a very complex structure.

Pic 2.7 :- tubular space frame chassis

Monocoque chassis:- it is also called structural skin, is a structural system in which loads are
supported by an objects external skin, similar to an egg shell. The word monocoque is a French
term for “single shell” or “single hull”. It is a structure which integrates body and chassis together
to form a composite structure which has better stiffness as well as weight advantage.

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 Pic 2.8 :- monocoque chassis
ULSAB:- it stands for ultra light steel auto body. Basically it has the same structure as a
conventional monocoque. What it differs from its donors is in minor details- the use of
“hydroform” parts, sandwich steel and laser beam welding.

Pic 2.9 :- ULSAB chassis

Hydroforming:-

Hydroforming is a cost- effective way of shaping ductile metal such as aluminium,brass, low alloy
steels, stainless steel into light weight, structurally stiff and strong pieces. One of the largest
application of hydroforming is the automotive industry, which makes use of the complex shapes
possibly by hydroforming to produce stronger, lighter, and more rigid unibody structures for
vehicles.

Car body style :-

 Sedan

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  Saloon
 Hatchback
 SUV

Sedan:- it’s a passenger Car in a three box configuration with separate compartments for engine ,
passenger, and Cargo.

Sedan's first recorded use as a name for a car body was in 1912. The name comes from a 17th century
development of a litter , the sedan chair, a one person enclosed box with windows and carried by porters.

Variations of the sedan style body include: closed coupled sedan, club sedan, convertible sedan, fastback
sedan, hardtop sedan, notchback sedan and sedanet/sedanette.

Pic 2.10 :sedan car body

Saloon :- a saloon vehicle is a four door car where the body is easily seen as being split into three sections:

Front- usually containing the engine.

Middle- the main cabin for passenger.

Rear- the boot for storage.

Saloon comes from the French word salon, which just meant a large room. From there it followed that
automobiles with a largeish ,

Enclosed passenger compartment could also be referred to as a saloon.

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 Pic 2.11:- saloon car body

Hatchback:- hatchback means a car with a door across the full width at the back end that opens upward to
provide easy access for loading.

A hatchback car is a vehicle that has a large door in the back that swings upward, while many other
models also use this type of door, a hatchback car is traditionally looked at as a small couple to sedan size
car with a raise open door in the back instead of a trunk, which usually gives it more storage space. It has
two boxes and three pillars compartment.

Compact hatchbacks are very popular, and midsize lift backs relatively popular, in Europe. Hatchbacks are
also popular throughout Asia and North America , and is the most common body type for city cars and
economy cars sold in Asia.

The modern form of the hatchback body style was developed through the 1960s and rose popularity
through the 1970s.

Pic 2.12 : types of hatchback cars

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SUV:- it stands for sports utility vehicle. It is a category of motor vehicles that combine elements of road
going passenger cars with features from off road vehicles, such as raised ground clearance and four wheel
drive. A cross over SUV is defined as an SUV built with unibody construction, however in many cases
crossovers are simply referred to as SUVs.

SUVs are criticized for their impact on other road users and the environment. Elements of their design
introduce safety risks both to their drivers and to others, and they are considered a leading cause of the
increase in pedestrian deaths in the United States over the past decade. They’re typically less fuel efficient
than smaller vehicles, thus contributing more to global warming.

The predecessor to SUVs date back to military and low volume models from the late 1930s, and the four
wheel drive station wagons and carryalls that began to be introduced in 1949. The 1984 Jeep Cherokee is
considered to be the first SUV in the modern style. Most SUVs produced today use unibody construction,
however in the past many SUVs used body on frame construction.

During the late 1990s and early 2000s , the popularity of SUVs greatly increased, often at the expense of
the popularity of large sedans and station wagons. More recently, smaller SUVs, mid-size and cross-overs
have become increasingly popular. SUVs are currently the world’s largest automotive segment and
accounted for 36.8% of the world’s passenger car market in 2017.

The first mass produced unibody four wheel drive passenger car was the Russian 1955 GAZ-M20 Pineda
M-72 , which could be considered as the first crossover car. The 1977 lada niva was the 1st off road
vehicle use to both a unibody construction and a coil sprung independent front suspension. The relatively
compact niva is considered a predecessor to the crossover SUV and combines a hatchback like passenger
car body with full time four wheel drive, low range gearing and lockable center differential.

Nonetheless, unibody SUVs remained rare until the 1984 Jeep Cherokee was introduced and became a
sales success. The introduction of the 1993 jeep grand Cherokee resulted in all jeep SUVs models using
unibody construction, with many other brands following suit since mid1990s.

Today, most SUVs in production use a unibody construction and relatively few models continue to use a
body on frame construction.

SUVs are typically of two box design similar to station wagon. The engine compartment is up front,
followed by a combined passenger/cargo area. Up until approximately 2010, many SUVs models were
available in 2-door body styles. Since then manufacturers began to discontinue the 2-door SUVs models
as 4-door models became more popular. Only a few 2-door SUVs remain today.

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Pic 2.13 :- types of SUVs

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 Chapter 3 :- Fundamentals of chassis

Chassis- As we have already discussed that fully functional part of vehicle

where all the sub assemblies are installed on it which make the body
movable from place a to b.

Component of chassis:-

 Frame
 Suspension system
 Steering mechanism
 Radiator
 Engine/clutch/gear box
 Propeller shaft
 Differential
 Braking system
 Battery
 Silencer
 Fuel tank

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Steering mechanism:-

it is the collection of components, linkages, etc. Which allows any vehicle

to follow the desired course. An exception is the case of rail transport by
which rail tracks combined together with railroad switches provide the
steering function. The primary purpose of steering system is to allow the
driver to guide the vehicle.

Pic 3.2:- steering system

The most conventional steering arrangement is to turn the front wheels

using a hand operated steering wheel which is positioned in front of the
driver, via the steering column, which may contain universal joints, to
allow it to deviate somewhat from a straight line. Other arrangements are

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sometimes found on different types of vehicles, for example, a tiller or
rear- wheel steering.

Land vehicle steering:-

Basic geometry:-

 Ackerman steering
 Bell Crank steering
 Rack and pinion steering
 Short rack and pinion steering

The basic aim of steering is to ensure that the wheels are pointing in the
desired directions. This is typically achieved by a series of linkages, rods,
pivots and gears. One of the fundamental concepts is that of caster angle-
each wheel is steered with a pivot point ahead of the wheel; this makes the
steering tend to be self centering towards the direction of travel.

The steering linkages connecting the steering box and the wheel usually
confirm to a variation of Ackerman steering geometry, to account for the
fact that in a turn, the inner wheel is actually traveling a path smaller
radius than the outer wheel, so that the degree of toe suitable for driving in
a straight path is not suitable for turns. The angle the wheels make with
the vertical plane also influences steering dynamics as do the tires.

Pic 3.3:- steering geometry

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Watercraft steering:- ships and boats are usually steered with a rudder.
Depending on the size of the vessel, rudders can be manually actuated, or
operated using a servomechanism, or a trim tab/ servo tab system. Boats
using outboard motors steer by rotating the entire drive unit. Boats with
inboard motors sometimes steer by rotating the propeller pod only.
Modern ships with diesel electric drive use azimuth thrusters. Boats driven
by oars or paddles are steered by generating a higher propulsion force on
the side of the boat opposite of the direction of turn. Jet skis and
surfboards are steered by weight shift induced roll only.

The rudder of a vessel can steer the ship only when water is passing over
it. Hence, when a ship is not moving relative to the water it is in or cannot
move it’s rudder, it doesn’t respond to the helm and is said to have “ lost
steerage”. The motion of a ship through the water is known as “making
way”. When a vessel is moving fast enough through the water that it turns
in response to the helm, it is said to have “steerage way”. This is why
boats on rivers must be always be under propulsion, even when travelling
downstream.

Aircraft and hovercraft steering:- Airplanes are normally steered by the

use of ailerons to bank the aircraft into a turn; the rudder is used to
minimize adverse yaw, rather than as a means to directly cause the turn.
Missiles, airships and large hovercraft are usually steered by rudder and /
or thrust vectoring. Small sport hovercraft have similar rudders, but steer
mostly by the pilot shifting their weight from side to side and unbalancing
the more powerful lift forces beneath the skirt. Jet packs and flying
platforms are steered by thrust vectoring only. Helicopter are steered by
cyclic control, changing the thrust vector of the main rotor, and by anti-
torque control, usually provided by a tail rotor.

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Chapter 4:- steering ratio and geometry

Steering ratio refers to the ratio between the turn of the steering wheel (in
degrees) or handlebars and the turn of the wheels (in degrees).

The steering ratio is the ratio of the number of degrees of turn of the
steering wheel to the number of degrees the wheel turn as a result. In
motorcycles, delta tricycles and bicycles, the steering ratio is always 1:1,
because the steering wheel is fixed to the front wheel. A steering ratio of
x:y means that a turn of the steering wheel x degree causes the wheel to
turn y degree. In most passenger cars, the ratio is between 12:1 and 20:1.
For example, if one complete turn of the steering wheel, 360 degrees,
causes the wheels to turn 24 degrees, the ratio is then 360:24= 15:1.

A higher steering ratio means that the steering wheel is turned more to get
the wheels turning, but it will be easier to turn the steering wheel. A lower
steering ratio means that the steering wheel is turned less to get the wheels
turning, but it will be harder to turn the steering wheel. Larger and heavier
vehicles will often have a higher steering ratio, which will make the
steering wheel easier to turn. If a truck had a low steering ratio, it would
be very hard to turn the steering wheel. In normal and lighter cars, the
wheels are easier to turn, so the steering ratio doesn’t have to be as high.
In race cars the ratio is typically very low , because the vehicle must
respond than in normal cars. The steering wheel is therefore harder to turn.

Another use of the term steering ratio is for the ratio between the
theoretical turning radius based on ideal tire behaviour and the actual
turning radius based on real tire behaviour. Values less than one, where
the front wheel side slip is greater than the rear wheel side slip , are
described as under steering equal to one as neutral steering; and greater
than one as over steering. Values less than zero, in which the front wheel
must be turned opposite the direction of the curve due to much greater rear
wheel side slip than front wheel have been described as counter steering.

Variable steering ratio is a system that uses different ratios on the rack in a
rack and pinion steering system. At the center of the rack , the space
between the teeth are smaller and the space becomes larger as the pinion
moves down the rack. In the middle of the rack there is a higher ratio and
the ratio becomes lower as the steering wheel is turned towards the lock.
That makes the steering less sensitive when the steering wheel is close to
its center position and makes it harder for the driver to over steer at high

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speeds. As the steering wheel is turned towards lock, the wheel begin to
react more to steering input.

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A steering quickener is used to modify the steering ratio of factory
installed steering system, which in turn modifies the response time and
overall handling of vehicle. When a steering quickener is employed in an
automobile, the driver of the automobile can turn the steering wheel a
smaller degree compared to a factory installed steering system without a
steering quickener , to turn the vehicle through same distance. On the
other hand, the steering effort needed will greatly increase. If the
automobile is equipped with Power steering, overloading the power
steering pump can also be a concern.

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Steering geometry of front wheels in atv:-

This design report elaborates the engineering and design process behind steering system
for All-Terrain Vehicle. The steering system allows the driver to guide the moving
vehicle on the road and have full control over it. The driving of vehicle must not be
tedious to the driver thus it is required to have the less steering effort with quick response
capability. This can be possible by varying and iterating different parameters like castor,
KPI, trackwidth, wheelbase etc. In addition the steering system also provides the
feedback from the road surface which utilizes the concept of scrub radius, pneumatic
trails and mechanical trails which also inculcate the self-centering in the tire behaviour at
dynamic condition. These feedback system from the road surface guides the driver to
perfectly and accurately steer the vehicle in the required manner. After undergoing
number of iteration considering all the causes , effects and the past experience the final
geometry is finalized. The designing , dimensioning and manufacturing of the parts are
done considering the serviceability, mechinability, sustainability and most important
interchangeability of the component. In addition report contains effects of other system
on steering characteristics and how they will help in the development of whole system.

Steering system is a system that helps us to guide the vehicle in a specific direction. It
provides the driver freedom to turn the vehicle accordingly as well as coordinate it. This
system owes a great importance in overall automobile performance as turning a vehicle is
a important characteristics when it comes to driving. Steering system are manual , power
assisted and most advanced automatic. Steering system works on linkage system.
Linkages accept the input from driver and helps in providing the output at tires resulting
in turning.

The law governing the turning motion of vehicles is called the Ackermann law, which
states that while negotiating the turn the inner wheel turns through greater angle than rear
wheel. This system was invented by German carriage builder Georg Lankensperger
which was applied by the Rudolf Ackermann in 1818 for horse-drawn carriages.
Ackermann introduced a law for perfect steering and all steering system are designed
considering this law

For the driving to be less tedious and more comfortable the design considers driver
ergonomics. By certain trials with driver, we confirmed angle of steering wheel to be 390
with horizontal plane.

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Regarding column position, While designing steering geometry we have done many
iterations regarding angle of steering column, one of which was using U-joint for good
ergonomics, also as there was clearance considerations of brake pedal and acceleration
pedal but, later due to change in rule of pedal by regulating body SAE BAJA India, we
shifted our steering geometry from using U joint to straight column

Steering Ratio and C-factor The steering ratio refers to change in tire angles per degree
rotation of steering wheel where C-factor refers to rack travel per unit rotation of steering
wheel. Calculating the steering ratio and C-factor using the following formulae,
1 steering ratio = sin−1 {( C − Factor steering Arm length × 360) }
By calculating using above formulae steering ratio is 2.69, which ultimately results in the
responsive steering as the single degree rotation of steering wheel will results in 2.69
degree tilt of wheel

The parameters scrub radius, mechanical trail, kingpin inclination and castor angle
influences the steering effort. The positive castor angle increases the steering effort
whereas the negative reduces the same, but the negative castor has a self-steering
characteristics which results in the phenomenon called as Hard Steering. In this vehicle’s
front tires are capable of turning automatically resulting in requirement of large effort to
keep the steering wheel and tire to stabilize. The vehicle have positive castor which is
more stable than the negative castor but required the more effort. The hard steering is also
influenced by the scrub radius thus an optimized value of castor , kingpin inclination and
scrub radius . The mechanical trail is also responsible for the influencing the steering
effort, more the mechanical trail more will be the effort and vice versa. Also the tire
contact patch increases and reduces with increase and decreased in the mechanical trail.
Thus it required to have optimized value of mechanical trail.

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Conclusion:-

The chief aim of the internship for ATV vehicle is meant for work ethics
and for safety legislation. Which specifies engineering control, and
design out hazards. These were more effective than administrative control
and sought change of personal protection major . Improving the
engineering and design features of ATV is mainly aim at reducing fatality
rate and injury rates.
The designing purpose of the ATV is to make manufacture of off road
vehicle that could help in transportation in hilly areas , farming field and
as a reliable experience for enthusiast .It was taught us, how the special
focus will be given on preparation of ATV, based on chassis, drive-by
train and suspension . During the entire design process, emphasis were
given on consumer interest, innovativeness, inexpensive and effective
methods which was our primary goal.
The major objective of framing design is to take care of the safety at all
times. The chassis design need to be prepared for the impact created for
any crash or rollover. It must be strong and durable taking to the weight
distribution and for better performances. The outsider must be 2.54cm ,
thickness 0.30cm bending stiffness 3791.1 Nm ², bending strength 467.4
Nm , weight per m 1.686 kg .The material used must be 4130 steel which
is a chrome molly steel that has greater strength to weight ratio .
Besides this there is a need of final element analysis such as elasticity
problem, stress and strain, fields transient dynamism , frequency of
vibration.
Loading analysis –

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It needs to analyze proper impact forces and crash roll standard . It
assumes that in worst case if collision will be seen then the vehicles runs
into stationary object.
Roll cage-
FEA(Final element analysis) of roll cage depends on the greater torsional
stiffness to ensure less deflection under dynamic loading and enhance
performances. The calculation of static analysis of roll cage based on
frontal impact, rear impacts, side impact, rollover test ,1 wheel bump test ,
torsional rigidity analysis and heave analysis . The use of AISI4130 alloy
steel are made as its young modules-205GPa , Poisson ratio 0.27 to 0.29
and the weight of vehicle is taken to be 272 kg . Max deformation varies
from 0.46mm to 2.95mm.

Suspension design
Designing of suspension significantly affect the comfort, safety and
maneuverability contributing to vehicles for handling and braking and
driving pleasure . It depends on maintaining correct wheel alignment .
Front suspension-
It is double arm wish bone type suspension with specious mounting
position, load bearing capacity and better chamber recovery .
Rear suspension-
It is of two type -swing arm CAD model-CATIAV5R20
Which may be monoshock mounting on swing arm which is
advantageous due to ease of adjustment as there is only single damping
unit and smaller un sprung mass. - Wish bone arm
These are proved to be capable of handling the stress exerted on them in
extreme situation .
Steering mechanism
To achieve the correct steering two type of mechanism are used they are
the
Bump and roll steer
Davis Ackerman mechanism
Ackerman mechanism is used generally for application of lower
condition ,where the speed seldom exceed 60kmph . Here the angle in

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which the steering arm makes with the Centre line can be found out
geometrically by drawing CATIA which is virtually VSR 20 by assuming
the position of tie rod fixed on knuckle and extending wishbone axles to
meet at the instantaneous center with the help of steering angle .
Bump and roll steer- Steer with ride travel is very common in all terrain
scenario, steer with ride travel is undesirable because when the wheel steer
and it runs over a bumps or, when the car rolls in a turn the car will travel
on a path that a driver didn’t select intentionally .
Braking system
The purpose of the braking system is to increase the safety and
maneuverability of the vehicles. In order to achieve maximum
performance from the braking system the brakes have been designed to
lock up all four wheels at the same time.
Design –
The braking system is composed both internal expanding drum brakes and
disc brake. The drum brakes are installed at the two front wheel and a
single rotor is mounted on the rear axle to satisfy the braking requirements
in terrain track , speed limits driver ergonomics and other rule book
constraints .
The front drum brakes are mounted on each wheel of internal radius 2.5
inches having a brake lining width of 3mm . The distance between pivot
point of both the brake shoes and cam is 3.93 inches. At the rear axles we
are using disc brakes due to fact that we require a effective braking at the
rear. It is also to our advantage that even if the front brake fail in worst
case scenario, braking power is still available to the driver. The rear brake
is composed of 5 inch diameter disc and the dual piston 1.5 in diameter
caliper.
FEA (final elements analysis) of disk brake help us ascertain the
importance of hole in design of disc . Boundary conditions is that the outer
edge is 40°c and inner is also same. Thermal load is 700°c . For drum
brakes Driver effort 25 lbs. ,liver ratio 6.3 :1 , coefficient friction is 0.5 ,
internal radius of drum is 2.5 inch, wide brake lining 3mm , pivot point to
CAM distance 3.93 inches.
For disc brake diver effort 80 lbs. ,pedal ratio 4.66:1 ,I’d master cylinder
14.043 mm ,I’d caliper 38.23 mm, diameter of rotor 5 inch .
Drive terrains design

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The drive terrains includes the engine, transmission and the axils for
transmitting the power to the wheels . The drive terrains of a vehicle is the
group of components that delivers power to the driving wheels ,this
exclude the engine or motor that generate the power . In contrast ,the
power terrains is considered as including both engine or motor and the
drive terrains .
Shifter transmission –( Manual gear box)
The shifter transmission has high output and power transfer. The power is
more easily controlled on with the gear shifter and desired gear can be
chosen at anytime. The main advantage of shifter transmission is that it is
tried and tested in many previous vehicles besides it has a high output
also. Therefore we have decided to use the shifter transmission. We have
studied transmission of various four wheeler and other small vehicle but to
meet our requirements only maruti and, Honda prove to be more fruitful.
Tyres and rims –
Traction is one of the most important aspect of both steering and getting
the power to the ground. The ideal tyre as low weight and low internal
forces. In addition it must have strong traction on various surfaces and be
capable of providing power while in puddles .
Function
Supports weight
Transmit vehicle propulsion
Soften impact from roads
Tyres
Keeping mind on all above mentioned aspects we studied about various
types of tyre available in the market and decided to use 2 -ply duro rating
tyre , tubeless tyre and that have got specific trade pattern so as to provide
a very strong and firm grip on all kinds of surfaces as well as sturdy
enough to absorb various bumps and depression on tracks.
After going through the engine, for transmission some basic torque and
angular velocity calculation are required, hill climb maneuverability,
transmission of maximum power and endurance have to be decided to find
the suitability of tyre .
Rims

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The rims shall be made of aluminum to minimize the Unsprung weight by
reducing the width of the rim the inertia will be directly decrease and
subsequently this will also reduce the overall weight. The diameter of all
four rims will be designed in such a way that it will be cost effective and
be customized as for own suitability .

Wheel end
The wheel end is made up of rim ,hub , disk -drum mild bearing and
knuckle sequence . There compatibility with each other is a major design
issue as this part gives safes to the vehicles .
Electrical system
The electrical system for the vehicles is designated to fill two key
purpose. First the electronic system supports . The mandatory safety
equipment, specifically the brake light and kill switch circuit .
Component of electrical system-
Battery- A maintenance pre lead storage battery is an electro chemical
device that produces voltage and delivers electric current. The electro
chemical reaction changes chemical energy to electrical energy and is
basis of all automotive vehicles. Specifications-9v ,6Ah.
Purpose- electricity from battery is used to operate lighting, or ignition
and other electrical system.
Spark plug-
It is used to ignite the fuel inside the cylinder of petrol engine.
Specifications- SIMR8A9(MGK).
Reverse light and alarm-
Since the vehicles are to be equipped with reverse light ( white colour
visible at minimum distance of 10m from vehicle ). Reverse alarm
installed for safety reason which shall operate when the reverse gear is
engaged.
Kill switch
This kill switches are able to cut off all the electrical connection including
ignition system and are rigidly mounted near the steering handle where the

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driver can easily control it. Second kill switch is placed on the left side of
the vehicles near driver seat .
Brake light
The brake light is installed at the back of the vehicles red in colour which
is clearly visible from the rear and is visible in very bright sunlight and is
mounted between the wheel center line to serve the purpose of indicating
that the driver has applied break and the vehicles tends to stop .
Electrical start
The modern starter motor is either a permanent magnet or a series or
series-parallel wounded direct current electric motor with a solenoid
switch (similar to relay) mounted on it. When current form the starting
battery is applied to the solenoid, usually through a key operated switch, it
pushes out the drive pinion on the starter, drive shaft and meshes the
pinion with the ring bear on the fly wheel of the engine .
Driver safety and ergonomics
 For better prospective we have further improvise our design
for the comfort and wellbeing of the driver. Vehicles will be
provided with spring support installed in the front of vehicle to
absorb energy from collision. Two fire extinguisher and to kill
switches are specified in the rule book will also be used for the
case of emergency.
Ergonomics include the foam padding of the front, rear and side body
panels ,gear shifting indicator, turn light indicators ,standard rear view
mirrors and such other things . ISI grade brake lights will be installed in
the ATV with proper insulation in the vehicles which allows to
successfully complete the ATV.
The objective of designing high safety and low cost production ATV
seems to be accomplished through the training imparted to us we are
indebted to the agency who had given the brief ideas about design which
is conceptualized based on the personal experiences and intuition. The use
of engineering principles and design process help us to verify and to create
a vehicle with optimal performance, safety manufacturability and
ergonomics. The process of designing include using solid works, CATIA
software packages to the model which will simulate and assist in analysis
of completed vehicles . The effort and endeavor given for this design will
give us a future direction to make any necessary changes in any vehicles
based on this principle .

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Our sincere thanks for devoting his valuable time for which he will be
always remembered by us. We solicit his presence in future as an when it
will be needed by us.

BIBLIOGRAPHY

1. https://www.wikipedia.org/

2. http://amzautomotive.com/

3. https://pixabay.com/

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4. https://unsplash.com/

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