Career Episode 1

Design and Analysis of ATV Frame

1.1 Introduction
 Project type: Academic
 Duration: insert
 University: Jawaharlal Nehru Technological University
 College Name: insert
 Location: Hyderabad, India
 Position: Position
 Supervisor: insert
1.2 Background
1.2.1
All-Terrain Vehicle (ATV) is a vehicle that can travel on low-pressure tires and has handlebars
for steering control. It is also known as a quad bike. It is built in such a manner that it can
traverse any terrain with ease. ATVs are typically designed for a single rider, while research is
being conducted to accommodate more than one passenger. It's similar to a motorcycle, but the
second seat provides more stability. In general, there are four wheels, and the number of wheels
can be raised for particular purposes. The ATV's strength is determined by the strength of the
frame or chassis. The chassis is the most significant section of the vehicle since it serves as the
vehicle's backbone and supports all mechanical components. The chassis houses all of the
vehicle's components, including the engine, steering system, suspension, differentials, and so on.
The chassis must be composed of a material that can bear a lot of force, vibrations, and so on.
The chassis should be constructed with ergonomics, comfort, affordability, and weight in mind.
ATVs go over a variety of terrain, they must be safe and comfortable.
The frame or chassis of the ATV was created and examined in this project utilizing SolidWorks
and ANSYS software. The two distinct materials were used for the analysis, and the findings
obtained from each were compared. The primary components and materials utilized in the
building were investigated and chosen. The design calculations for the chassis size and other
applicable forces were completed. The SolidWorks design program was used to generate the 3D
model of the frame. Finally, static structural analysis was carried out using the 3D model of the
frame to determine the stress, strain, and deformation values.
1.2.2 Objectives
This project's major goal was to design and assess the All-Terrain Vehicle using SolidWorks and
ANSYS technologies. The following are the additional particular objectives that were included:
 To choose the optimum high-strength material for the chassis.
 To create an All-Terrain Vehicle that was both cost economical and efficient.
 To improve the ATV's safety and performance.
1.2.3 Organizational Chart

Jawaharlal
Nehru
Technological
University

Insert college

Department of
Mechanical
Engineering

Project
Manager

Group Leader
(Vutukuri Team
Arun Kumar Members
Reddy)

Figure 1: Organizational Chart

1.2.3 Duties
 To examine previous research papers, journals, and articles in order to get a thorough
grasp of the All-Terrain Vehicle, its many varieties, and components.
 To choose the optimum materials for the chassis as well as the vehicle's key components.
 To do design calculations for each component and calculate frame dimensions.
 To produce a 3D model of the chassis frame using the SolidWorks program
 To do a static analysis of the chassis in ANSYS and compare the results.
1.3 PEA
1.3.1
I began my effort by reviewing the literature on All-Terrain Vehicles. First, I examined the
various types of all-terrain vehicles using prior research works, research papers, various
publications, and so on. I also read several periodicals and publications about the primary
components of an all-terrain vehicle and their operating mechanisms. Through earlier study, I
also enhanced my understanding of the material selection technique and studied the general
materials used in the production of all-terrain vehicles. In order to accomplish this project
successfully, I also learned about the design technique, design concerns, and so on. Through
previous work connected to it, I also learnt about the design calculations of each component of
the vehicle. I also learned about the SolidWorks design software. I also learned more about
analytical software, such as ANSYS.
1.3.2
After finishing the research on previous work linked to the all-terrain vehicle, I began to pick the
primary components and materials for the model's construction. First, I chose the primary
components of the all-terrain vehicle. I chose the chassis, engine, differentials, gears, steering
system, and suspension, among other things. I opted to use the vehicle's four wheels. I chose
major chassis elements such as the rear roll hoop, lateral cross member, front bracing member,
and so on. I also chose the secondary chassis members, which included the lower frame member,
under seat member, and so on. Following that, I began the material selection procedure. I
discovered that the following materials were often utilized in the vehicle's construction: steel
1018, steel 4130, carbon fiber, and E-glass Epoxy, among others. Following that, I chose steel
1018 and carbon fiber for the chassis. Following that, I chose SolidWorks design software to
make a 3D model of the frame.
1.3.3
After finishing the component selection, I began the design computation for the all-terrain
vehicle. Before beginning the computations, I studied the various parameters. I evaluated how
various loads effect on the chassis, such as the load of the passengers, vertical loads, load due to
cornering force, load due to vehicle components, and load due to braking torque, among others.
After that, I began calculating the rear impact force. I analyzed the mass, beginning velocity, and
end velocity for this, and then computed the work done using an appropriate equation. After that,
I estimated the displacement by taking into account the impact time and maximum velocity.
After that, I estimated the rear impact force by dividing the work done by the displacement. After
that, I computed the side effect in the same way. After that, I began calculating the frame's
dimensions. I analyzed both the major and secondary members' circular cross sections.
Following that, I assessed the diameter and thickness of the chassis' major and secondary
members. Following that, I assessed the chassis' length, breadth, and height. Then I examined the
weight of the frame as well as the ground clearance.
Insert calculation
1.3.4
After completing the design calculations for the all-terrain vehicle, I began creating a 3D model
of the vehicle in SolidWorks. I started by designing the vehicle's chassis. For this, I launched the
SolidWorks application and selected the appropriate units for dimensioning. Following that, I
chose to model in 1:1 scale. Then I choose 3D drawing and began to design the chassis profile. I
used the line tool in the toolbar to make the 3D sketch profile of the chassis. I made a rectangle
on the left face, another rectangle in the middle top, and three rectangles on the bottom with
appropriate dimensions. Following that, I generated a slope line linking the top rectangle to a
specific height, as well as a new rectangle. I made two parallel lines from the middle top
rectangle to the right side, increasing the space between them, and then linked the two lines to
the bottom rectangle with a vertical line. In a similar fashion, I finished the 3D drawing. Then,
using the SolidWorks weldments features, I provided the various size circular cross section the
individual line/member of main and secondary parts. After that, I used the SolidWorks line,
fillet, circle, extrude boss, extrude cut, and other features to make the other car components.
After that, I used the assembly feature to join all of the pieces together. Then I saved the chassis
file alone in. IGES format for further analysis in Ansys.
Insert model
1.3.5
After finishing the 3D model of the all-terrain vehicle in SolidWorks. I began the static analysis
for the vehicle's main component, the chassis. I brought the 3D model of the chassis into
ANSYS. After that, I assigned the carbon fiber material's attributes. Then, in order to obtain
exact results, I mesh the model to divide the entire domain into smaller components. I used fine
tetrahedral meshing to mesh the model. I also reduced the mesh size in a few important areas.
After that, I began the setup procedure. I did this by applying the computed load and fixed
support to a specific portion of the model. The simulations were then run. Then I examined the
effects of equivalent stress, strain, various forces, and overall deformations, among other things.
Following that, I examined the model for steel 1018 materials in a similar manner. Then I began
comparing the outcomes of the models created from the two materials. Then I discovered that the
findings of both material models were all within safe ranges. However, I obtained the findings
from the carbon fiber model were good, and this material was chosen for the fabrication of the
chassis.
Insert analysis
1.4 Technical problems and solutions
1.4.1
I received the error when attempting to solve the simulations, and the simulations would not
progress. I saw the error message and looked it up on the internet as well as in my previous
work. I also raised the issue with my boss. After studying the model, he proposed that all of the
model's joints be checked. Then I began a thorough examination of the 3D model of the chassis
and discovered that welding three lines at a junction was incorrect. Then I correctly welded the
chassis part and conducted the simulations. It took some time to solve, but I was able to acquire
the results of the simulations.
1.4.2
While viewing the simulation results, I realized that the deformation achieved was far too great,
suggesting that the model was not safe After that, I discussed the issue with my coworkers but
came up with no solutions. Then I decided to talk to my supervisor about the problem. Then I
described the situation with him, and he examined the model and problem. Then he advised that
the model's surface be fine-tuned. Then, following his guidance, I fine-tuned the surface of the
frame with the SolidWorks fillet tool. The simulations were then run, and the deformation value
was found to be within the safe limits.
1.5 Creative activities
Using SolidWorks and ANSYS software, I developed and analyzed the chassis of the all-terrain
vehicle. To avoid problems, I welded all of the frame's members precisely. I also made use of the
fine meshing. I also fine-tuned the model's surface with the SolidWorks fillet tool.
1.6 Project Management and Codes
I completed my responsibility as a team leader. I prepared a plans and strategies for all the task
of the project and all the tasks were completed according to the design plan. I assigned the
project’s task to all my team members and monitored all the completed and ongoing task of the
project. I collected all the required information and the materials that were needed for the
project. I was in regular touch with my supervisor to discuss on various aspects of project. I
made friendly working environment in the project. I discussed all the problems that was faced in
the project with my supervisor for his valuable suggestions to solve it. After successfully
completing the assignment, I drafted a full report and forwarded it to the university.
I used
1.7 Summary
The design and analysis of All – Terrain Vehicles was completed successfully. All the
components and materials that was needed for the project was selected based on economy, less
weight, and function ability. The design parameters for the chassis size and other applicable
forces were completed. The 3D model of the chassis frame was designed using the SolidWorks
program. The static analysis of the chassis was conducted in ANSYS, and the results were
compared. The effects of equivalent stress, strain, various forces, and overall deformations were
analyzed for steel 1018 and carbon fiber model. It was found that the findings of both material
models were all within safe ranges. However, the results of stress, strain, deformation of carbon
fiber model were good, and this material was chosen for the fabrication of the chassis. The
design of All-Terrain Vehicle chassis was noticed to be both cost economical and efficient. The
safety and performance of ATV was improved by the appropriate design and materials selection.
I learned to design the model of mechanical components in SolidWorks and its structural
analysis in ANSYS. I improved my skills and ability in fluent communication, project
management and problem solving.