COMPLETE REPORT (Material Machanical Engineering Diploma)

AHS Industries “Bringing the future to you”
TABLE OF CONTENTS
No. Title Page

INTRODUCTION
1 - Definition of Amphibious Vehicle 1-3
- History
THEORY
- Buoyant Force
2 - Archimedes’ Principles 4-7
- Stability
- Strength of chassis
3 PROBLEM STATEMENT 8
4 OBJECTIVE OF PRODUCT 8
SCOPE AND LIMITATIONS OF THE
5 9
PRODUCT
METHODOLOGY
6 - Define Problem 10 - 11
- Gathering Information
GENERATE MULTIPLE SOLUTIONS
7 12 - 15
- Sketches
ANALYZE AND SELECT SOLUTION
8 16 - 17
- Conclusion
9 REFERENCES 18
Page 1
DEFINITION OF AMPHIBIOUS ATV
FIGURE 1 Land Tamer amphibious 8x8 remote access vehicle for disaster relief.
An amphibious vehicle is a transport that can move both on water and ground
terrain.There is variety amphibious vehicle such as quadski which is initially an ATV that
is combined with the concept of a jet ski.One of the most famous amphibious vehicle is the
hovercraft.It took the shape of an inflatable boat .It uses a high power fan to move an land
instead of tires.These amphibious vehicle is widely used for military purposes.In a simpler
word is an amphibious vehicle is any vehicle that move on water and another terrain
whether on airway or ground road.
Page2
HISTORY
(Amphibious) ATVs were made in the United States a decade before 3- and 4-wheeled
ATV's were introduced by Honda and other Japanese manufacturers. After the presentation
of the Jiger in 1961, numerous manufacturers offered a number of similar small off-road
vehicles, that were designed to float and were capable of traversing swamps, ponds and
streams as well as dry land. Because they were smaller and much simpler in construction
than (amphibious) cars, they were much cheaper to produce and quickly gained
considerable popularity. By 1970 there were almost 60 companies producing amphibious
6x6 vehicles. There was even a professional racing association dedicated to the 6x6,
holding numerous competitions across the USA. These amphibious vehicles were
originally called all-terrain vehicles - or ATVs.
In the early 1970s however there was a rapid decline in sales of this type of ATVs, forcing
most manufacturers to cease production. Reasons were:
- The 1973 oil crisis prompted many North Americans to tighten their belts and spend
less on recreational vehicles.
- The introduction of the 1970 Honda ATC90 threewheeler offered a fun alternative at
some $600 / $800, when a 6x6 would cost $1,500.
- The simple construction of the original ATVs attracted many companies that were
interested in making a quick buck, but underestimated the engineering needed,
leading to poor quality products, that gave the industry a bad reputation.
With most models utilizing 2-stroke engines, the 6x6's didn't run well unless properly
maintained. 4-strokes were available, however, they were under-powered with at most 12
hp. Only a small number of manufacturers of this type of vehicle remain today.
Page3
THEORY
Buoyant Force
Diagram 2 shows the buoyant force theory
Buoyancy is an upward force exerted by a fluid that opposes the weight of an

immersed object. An object whose density is greater than that of the fluid in which it is
submerged tends to sink. If the object is either less dense than the liquid or is shaped
appropriately (as in a boat), the force can keep the object afloat. This can occur only in a
reference frame which either has a gravitational field or is accelerating due to a force other
than gravity defining a "downward" direction (that is, a non-inertial reference frame).
The center of buoyancy of an object is the centroid of the displaced volume of fluid.
The weight of the displaced fluid is directly proportional to the volume of the displaced
fluid. Thus, among completely submerged objects with equal masses, objects with greater
volume have greater buoyancy. Buoyancy reduces the apparent weight of objects that have
sunk completely to the sea floor. It is generally easier to lift an object up through the water
than it is to pull it out of the water. [1]
Page4
Archimedes’ Principle
Archimedes' principle may be stated thus in terms of forces:

Any object, wholly or partially immersed in a fluid, is buoyed up by a force equal to
the weight of the fluid displaced by the object.
With the clarifications that for a sunken object the volume of displaced fluid is the
volume of the object, and for a floating object on a liquid, the weight of the displaced
liquid is the weight of the object.
More tersely: Buoyancy = weight of displaced fluid.
The principle that Buoyancy = weight of displaced fluid remains valid.
The weight of the displaced fluid is directly proportional to the volume of the
displaced fluid (if the surrounding fluid is of uniform density). Thus, among completely
submerged objects with equal masses, objects with greater volume have greater buoyancy.
This is also known as upthrust.
Assuming Archimedes' principle to be reformulated as follows;
then inserted into the quotient of weights, which has been expanded by the mutual volume
yields the formula below. The density of the immersed object relative to the density of the
fluid can easily be calculated without measuring any volumes:
Example: If you drop boat into water, buoyancy will keep it afloat. [1]
Page5
Stability
Diagram 3 shows the stability theory

Illustration of the stability of bottom-heavy (left) and top-heavy (right) ships with
respect to the positions of their centres of buoyancy (CB) and gravity (CG)
A floating object is stable if it tends to restore itself to an equilibrium position after a

small displacement. For example, floating objects will generally have vertical stability, as
if the object is pushed down slightly, this will create a greater buoyancy force, which,
unbalanced by the weight force, will push the object back up.
Rotational stability is of great importance to floating vessels. Given a small angular

displacement, the vessel may return to its original position (stable), move away from its
original position (unstable), or remain where it is (neutral).
Rotational stability depends on the relative lines of action of forces on an object. The
upward buoyancy force on an object acts through the center of buoyancy, being the
centroid of the displaced volume of fluid. The weight force on the object acts through its
center of gravity. A buoyant object will be stable if the center of gravity is beneath the
center of buoyancy because any angular displacement will then produce a 'righting
moment'.
The stability of a buoyant object at the surface is more complex, and it may remain
stable even if the centre of gravity is above the centre of buoyancy, provided that when
disturbed from the equilibrium position, the centre of buoyancy moves further to the same
side that the centre of gravity moves, thus providing a positive righting moment. If this
occurs, the floating object is said to have a positive metacentric height. This situation is
typically valid for a range of heel angles, beyond which the centre of buoyancy does not
move enough to provide a positive righting moment, and the object becomes unstable. It is
possible to shift from positive to negative or vice versa more than once during a heeling
disturbance, and many shapes are stable in more than one position.
Page6
Strength of Chassis
Diagram 4 shows the 1997 Polaris Xpress 300 chassis
Chassis is the supporting frame of a structure.It keep holds all of the other parts such
as the engine ,oil tank,and tyres so it will not fall apart .A strong chassis is most sufficient
in ATV designing as the vehicles is known to roll on an uneven rough ground.So,if an
ATV’s chassis is poorly built,it will less likely makes it useless.A strong ATV should have
a shape that can hold all the parts together firmly .It also important for safety.A strong
chassis should be able to absorb large amount of impact from colliding to the driver safe. A
safe chassis can help a driver to gain confidence to ride the ATV .It also act as an aero
device as the shape of the body design depends on its shape.
Page7
PROBLEM STATEMENT
How to make an ATV possible to move on both water and land smoothly?
OBJECTIVE OF PRODUCT
1. Produce CAD modeling assembly drawings and working/fabrication drawing using
CAD software following standard procedure.
2. Gain experience in basic product design process, including concept design, detailed
drawing and prototyping.
3. Gain experience in project management, teamwork and communication.
Page8
SCOPE AND LIMITATIONS OF THE PROJECT
TRANSITION
The ATV that is currently manufactured must be able to move amphibiously which is on
water and land. So it must have transition system that can make it change the its
mechanism to adapt to its terrain.
ENGINE SYSTEM
An ATV needs a very high performance engine that can make it move smoothly especially
on rocky area which require lots of force make a climb. Unfortunately, this kind of engine
cost a lot of money and using an electric engine would probably be a problem as it has less
horse power.
SHAPE
The design is crucial in making an amphibious vehicle as its requires the product to move
on two significant terrain. So the design made must be look into thoroughly so there will be
no problem appear.
PROPULSION AND MANEUVERING SYSTEM

Propulsion and maneuvering system is system that controls how the vehicle behave which
is how it moves.
TYRE AND SUSPENSION

Tyre and suspension is important for on land movement. It will affect how strong the grip
of the ATV while the suspension affects when moving on an uneven terrain which would
be bumpy.
DIMENSION
Dimension is how big or small the product will be. The problem is what is the most
suitable size for a one seater.
Page9
METHODOLOGY
GATHERING
DEFINE PROBLEM
INFORMATION
ANALYZE AND GENERATE

SELECT MULTPILE
SOLUTION SOLUTIONS
PRODUCE CAD DECISION

MODELLING MAKING
BILL OF
ESTIMATE COST
MATERIALS
OF PRODUCT
REPORT
Page
10
DEFINE PROBLEM
- How to make an ATV possible to move on both water and land smoothly?
- An amphibious ATV is a 4 wheel drive that can move both on water and land but the
ATV is not fully functional on water. So this project is to manufacture a product that
can make an ATV to possibly move on water.
GATHERING INFORMATION
1. Browsing the web to know the fundamentals of an ATV.
2. Go to the workshop and factory to see how an ATV is made.
3. Asking the the experts in ATV fields to seek solutions to make a good ATV.
Page
11
GENERATE MULTIPLE SOLUTIONS
PRODUCT DISADVANTAGES ADVANTAGES

 The steering is too hard to  Attractive design
handle thus use too much  Easy to make
MOBILIZER energy to maneuver transitions between land
 Slide when moving on and water
muddy road  High speed
 Engine caused too much  Low cost
pollution yet produce less  Simple design
TURBOBLASTER power
 Sluggish on water
movement
 The size of the vehicle is  Can withstand
too large of a single seater extreme condition
GONDOLA
 the transition system is such as blizzard
hard to use
Page
12
SKETCHES
PRODUCTS ADVANTAGES DISADVANTAGES

 The steering is too hard to  Attractive design
GONDOLA handle thus use too much  Can travel fast on both
energy to maneuver surface
 Slide when moving on  Easiness on making
muddy road transition between land
and water mode
Page
13
PRODUCT ADVANTAGES DISADVANTAGES

 Engine caused too much  Low cost
TURBOBLASTER pollution yet produce less  Design is simple
power
 Sluggish on water
movement
Page
14
PRODUCT ADVANTAGES DISADVANTAGES

 The size of the vehicle is  Can withstand extreme
MOBILIZER too large of a single seater condition such as blizzard
 the transition system is hard
to use
Page
15
MATRIX ANALYSIS SOLUTION
CRITERIA WEIGHTAGE TURBOBLASTER MOBILYZER GONDOLA

(%)
6 8 9
SAFETY 25 6 x 25 8 x 25 9 x 25
= 150 = 200 = 225
7 9 7
TRANSITION 13 7 x 13 9 x 13 7 x 13
= 91 = 117 =91
6 10 9
DESIGN 16 6 x 16 10 x 16 9 x 16
= 96 = 160 = 144
8 9 8
HANDLING 16 8 x 16 9 x 16 8 x 16
= 128 = 144 = 128
8 9 6
SPEED 15 8 x 15 9 x 15 6 x 15
= 120 = 135 = 90
9 10 7
ACCELERATION 15 9 x 15 10 x 15 7 x 15
= 135 = 150 = 105
585 / 100 906 / 100 783 / 100
TOTAL 100
= 5.85 = 9.06 = 7.83
Based on the Matrix Analysis Solution we focus our ATV more on

safety. This is to ensure our customer feel safe when riding the ATV.
We also focus on design and handling so that our customer easily
attract to our product. We focus the least to speed and acceleration
so that the product are just perfect to perform on land and water.
Page
16
RATING FACTOR
GRADE MARKS
EXCELLENT 9-10
GOOD 7-8
FAIR 5-6
POOR 3-4
UNSATISFACTION 0-2
Conclusion
Based on the matrix analysis solution made, we decided that the

mobilizer is chosen as the product for our project is Mobilyzer as it
has almost fit all the criteria needed to make a fully working ATV. It
is proven for its safety and can be ride safely. Despite the high score
in safety marks, it does not abandon the horsepower for speed
satisfaction. The brake, transition and manoeuvring are also good
enough to put it as a great ATV.
Page
17
MATERIAL SELECTIONS
 ALUMINIUM
Figure 3: Aluminium
Aluminium is the engineering material of choice for many applications. Properties

that make aluminium popular and suitable include, Light, Strong, High strength-to-
weight ratio, Resilient, Ductile at low temperature, Corrosion resistant, Non-toxic,
Heat conducting, Reflective, Non-sparking, Non-combustible.
Advantages Disadvantages
 Easy assembly  More expensive than

design steel
 Easy to fabricate  Difficult to weld
ALUMINIUM
 Precise, close  Prone to severe spring
tolerances back
 Complex, integral  Abrasive to tooling
shapes (aluminium oxide is
 Uniform quality very abrasive)
 Recyclable  Limited to certain
 Joinable by various geometric features
methods using economical
 Freedom of design processes.
Page
18
 FIBERGLASS
Figure 4: Fiberglass
A material made up of very fine fibers of glass. Fiberglass is resistant to heat and
fire and is used to make various products, such as building insulation and boat
hulls. It is because the fibers in fiberglass are capable of transmitting light around
curves, fiberglass is an important of fiber optics.
 Light weight  Sensitivity to shock

 High strength in  Less strength in
FIBER
tension compression
 Easy shaping
 Low thermal
expansion
 High resilience (can
be deformed
thousands of times
without fatigue)
Page
19
 PLASTIC
Figure 5: Plastic
A plastic material is any of wide range of synthetic or semi-synthetic organic solids

that are mouldable. Plastics are typically organic polymers of high molecular mass,
but they often contain other substances. Due to their relatively low coast, ease of
manufacture, versatility, and imperviousness to water
 Light in weight  Deformation under

 Easily moulded load
 Durability and  Low heat resistant
PLASTIC
strength and poor ductility
 Very good water  Produce toxic fumes
resistances when it is burn
 Electrical insulating
property
 Low thermal
expansion
Page
20
 MILD STEEL
Figure 6: Mild Steel
Mild steel is a carbon steel typically with a maximum of 0.25% Carbon and 0.4%-
0.7% manganese, 0.1%-0.5% Silicon and some traces of other elements such as
phosphorus, it may also contain lead or sulphur. Mild steel is a general term for a
range of low carbon steels that have good strength and can be welded into an
endless variety of shapes for uses from vehicles to building materials.
 Many shapes  Rust easily

MILD STEEL
available  Feed does not
 Wieldable required special
 Easy to shape skills.
 High stiffness
 Easy to weld
Page
21
Material analysis
1. For chassis
Characteristic Aluminum Mild steel
Hardness Low High
Corrosion resistance High low
Strong Low High
Tensile strength Low High
Toughness Low Low
Cost RM1000 RM1500
Easy processes Yes yes
2. For hull boat
Characteristic Fiber glass Plastic
Flexibility High Low
Hardness High Low
Corrosion resistance Low Low
Strong High Low
Toughness Yes Yes
Cost RM300 RM200
3. For steering
Hardness Low High
Corrosion resistance High Low
Strong Low High
Page
22
Toughness Low Low
Cost RM99 RM150
Easy processes Yes Yes
4. For chair
Characteristic Plastic Wood
Hardness Low High
Corrosion resistance Low High
Strong Low High
Tensile strength High High
Toughness High High
Cost RM100 RM200
Page
23
1. For propeller
Characteristic Aluminum Plastic
Hardness High Low
Corrosion resistance High Low
Strong High Low
Toughness High Low
Cost RM150 RM100
Easy processes yes yes
2. For pedal
Hardness Low High
Corrosion resistance high Low
Strong Low High
Toughness Low Low
Cost RM30 RM60
Easy processes Yes No
Page
24
1. For body
Characteristic Fiber glass Aluminum
Hardness High Low
Corrosion resistance Low High
Strong High Low
Tensile strength Low Low
Toughness High Low
Cost RM150 RM250
Easy processes Yes No
Page
25
Final choosing of material:
Part Material Properties Price
Chassis Mild steel  Readily available RM1500

 East to shape
Hull boat Fiber glass  Low weight RM300
 Good in mechanical strength
 High impact strength
 Weatherproof
 Low thermal expansion
 Long life
Steering Aluminum  Low density RM99
 Low weight
 High strength
 Excellent corrosion resistance
 Superior malleability
 Good electrical
 Easy to recycle
Chair Plastic  Low cost RM100
 Versatility
 Easy of manufacture
Propeller Aluminum  Low density RM150
 Low weight
 High strength
 Good electrical
 Easy to recycle
Pedal Aluminum  Low density RM30 X 2
 Low weight
 High strength
 Good electrical
 Easy to recycle
Body Fiber glass  Low weight RM150 X 4
 Good in mechanical strength
 High impact strength
 Weatherproof
Page
26
 Low thermal expansion

 Long life
 Anti-magnetic
Total price: RM2809
Page
27
DISCUSSION
1) CHASSIS
Figure 7: ATV chassis
Mild steel can be used in most project requiring a lot of steel. We choose mild
steel as a material for our ATV chassis. It is because of its poor resistance to
corrosion it must be protected by painting to prevent it from rusting. It is also
easily to welded. Mild steel is hard, yet malleable, making it the ideal choice for
the construction of chassis. It can be machined and shapes easily due to its
inherent flexibility.
Page
28
2) HULL BOAT
Figure 8: hull boat
We choose fiberglass as a material for our bull boat. It is because fiberglass has
a enough criteria such as has a low weight, waterproof material and low density
than water so our ATV can floating. It also good mechanical strength and high
impact strength compare than aluminium. Long lasting structure is one of
fiberglass properties. It also do not conduct electricity and maintaining
temperature. Next, it has a fire resistance and low thermal expansion. So, this
material is suitable to build bull boat with it.
Page
29
3) STEERING
Figure 9: Steering
For steering, we choose aluminium as a material. It is one of the best properties

of aluminium is that it is light weight but this does not affect its strength.
Aluminium is easy to work using most using machining methods. This material
take a long time to rust. So , it is suitable to make steering material.
Page
30
4) CHAIR
Figure 10: ATV seat
For chair, plastic are suitable material because it has low cost and also
versatility and imperviousness to water compare to wood. It also light in weight
and easily to moulded. Plastic also have a good durability and strength.
Page
31
5) PROPELLER
Figure 11: Propeller
For propeller we choose aluminium as a material because the characteristic is

suitable for our amphibious ATV such as high strength to make trust in the
water. This material also flex considerably under high loads. On the other hand,
it is a good on trolling motors and low horsepower outboards.
6) PEDAL
Figure 12: Pedal
Pedal is the important thing and must have a suitable material for it. We choose
aluminium because have a good strength. So we can put on the pedal a big force
to apply the concept of the pedal. It is also easy to shape and using machining
methods.
Page
32
Page
33
7) BODY
Figure 13: Body
For the ATV body, we choose fiberglass to cover all of the chassis. It will make
the ATV low density than water and float on the water like a boat. Fiberglass is
waterproof material that can make low density. Besides, fiberglass is a anti-
magnetic material and has low maintainance.
Page
34
Conclusion
As a conclusion, we can determine and conclude the suitable materials for this project
based on the toughness, tensile strength, hardness, corrosion resistance and performance of
the materials from this analysis of the selection materials. We also can improve our
knowledge about the properties of the materials selection in order to finish our project on
time. Then our group also get a lot of information and learned more about the history of
amphibious vehicle and many more. We can conclude that the objectives of this task have
been accomplished. Other than that, we have highlight the fact that the time management is
very important so we have to manage our time properly as to finish the task. So that we
didn’t do our work at last minute. During this assessment, we had enjoyed ourselves and
try to find and know the best materials as far as we can.
Page
35
REFERENCES
Page
36

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AHS Industries “Bringing the future to you”

No. Title Page

DEFINITION OF AMPHIBIOUS ATV

Diagram 2 shows the buoyant force theory

Buoyancy is an upward force exerted by a fluid that opposes the weight of an

Archimedes' principle may be stated thus in terms of forces:

The principle that Buoyancy = weight of displaced fluid remains valid.

Assuming Archimedes' principle to be reformulated as follows;

Diagram 3 shows the stability theory

A floating object is stable if it tends to restore itself to an equilibrium position after a

Rotational stability is of great importance to floating vessels. Given a small angular

Diagram 4 shows the 1997 Polaris Xpress 300 chassis

SCOPE AND LIMITATIONS OF THE PROJECT

PROPULSION AND MANEUVERING SYSTEM

TYRE AND SUSPENSION

ANALYZE AND GENERATE

PRODUCE CAD DECISION

GENERATE MULTIPLE SOLUTIONS

PRODUCT DISADVANTAGES ADVANTAGES

PRODUCTS ADVANTAGES DISADVANTAGES

PRODUCT ADVANTAGES DISADVANTAGES

PRODUCT ADVANTAGES DISADVANTAGES

MATRIX ANALYSIS SOLUTION

CRITERIA WEIGHTAGE TURBOBLASTER MOBILYZER GONDOLA

Based on the Matrix Analysis Solution we focus our ATV more on

Based on the matrix analysis solution made, we decided that the

Aluminium is the engineering material of choice for many applications. Properties

 Easy assembly  More expensive than

 Light weight  Sensitivity to shock

A plastic material is any of wide range of synthetic or semi-synthetic organic solids

 Light in weight  Deformation under

Figure 6: Mild Steel

 Many shapes  Rust easily

Characteristic Aluminum Mild steel

Hardness Low High

Corrosion resistance High low

Strong Low High

Tensile strength Low High

Toughness Low Low

Cost RM1000 RM1500

Easy processes Yes yes

2. For hull boat

Characteristic Fiber glass Plastic

Flexibility High Low

Hardness High Low

Corrosion resistance Low Low

Strong High Low

Tensile strength Low High

Toughness Yes Yes

Cost RM300 RM200

Easy processes Yes yes

Characteristic Aluminum Mild steel

Hardness Low High

Corrosion resistance High Low

Strong Low High

Tensile strength Low High

Toughness Low Low

Cost RM99 RM150

Easy processes Yes Yes

Characteristic Plastic Wood

Hardness Low High

Corrosion resistance Low High