An Internship Report on

ADVANCED TWO WHEELER TECHNOLOGY WITH “TVS”

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

Bachelor of Technology

In

MECHANICAL ENGINEERING

Submitted by

MD SHOAIB AHMED – 20H55A0312

Under the supervision of

Prof.Dr. P RAVI KUMAR

HOD, Dept of MECH

DEPARTMENT OF MECHANICAL ENGINEERING

CMR COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)

(NAAC Accredited with “A+” Grade & NBA Accredited)

(Approved by AICTE, Permanently Affiliated to JNTUH Hyderabad)

KANDLAKOYA(V), MEDCHAL ROAD, HEDERABAD – 501401

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CERTIFICATE OF COMPLETION

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 CMR COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)
(NAAC Accredited with “A+” Grade & NBA Accredited)

(Approved by AICTE, Permanently Affiliated to JNTUH Hyderabad)

KANDLAKOYA(V), MEDCHAL ROAD, HEDERABAD – 501401

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is certify that the Internship report entitled “ADVANCED TWO WHEELER
TECHNOLOGY WITH ‘TVS’ ” is a bonafide work done by MD SHOAIB AHMED
(20H55A0312) in partial fulfillment of the requirements for the award of the degree
of Bachelor of Technology in Mechanical Engineering, submitted to the Department
of Mechanical Engineering, CMR College of Engineering & Technology,
Hyderabad during the Academic year 2022-23.

Prof.Dr. P Ravi Kumar Prof.Dr.P.Ravi Kumar

HOD, Dept of MECH HOD, Dept of MECH
Internship Supervisor

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 ACKNOWLEDGEMENT

We are highly indebted and grateful to our guide Dr.P RAVI KUMAR, Head of department, Dept
of MECH, CMRCET for his excellent guidance and constant encouragement throughout for the
successful completion of the Internship.

We are obliged and grateful to thank Prof Dr.P.RAVI KUMAR, HOD Dept of MECH,CMRCET,
for his cooperation in all aspects.

We would like to thank Major Dr.V.A.NARAYANA, Principal, CMRCET ,for his support in the
course of this project work.

We would like to thank Shri Ch. GOPAL REDDY GARU, Secretary & Correspondent of
CMRCET, for his cooperation in all aspects during the course.

It gives immense pleasure in expressing our deep sense of gratitude to our project gudie Incharge,
Dr.P RAVI KUMAR, HOD ,Dept of MECH for his valuable suggestions in each and every
review during the course of my project.

Finally, we would like to thank all teaching and non-teaching staff members of the department, for
their cooperation and support throughout the duration of my course.

Ultimately, we owe all our success to our beloved parents, whose vision, love and inspiration has
made us reach out for these glories.

SIGNATURE:

MD SHOAIB AHMED (20H55A0312)

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 DECLARATION

We hereby declare that results embodied in this Report of Internship on “ADVANCED TWO
WHEELER TECHNOLOGY WITH TVS” are from work carried out by using partial
fulfillment of the requirements for the award of B-Tech degree. We have not submitted this Report
to any other University / institute for the award of any other degree.

SIGNATURE:

MD SHOAIB AHMED (20H55A0312)

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INDEX

SECTION DESCRIPTION PAGE NO

1 INTRODUCTION

1.1 WHAT IS AUTOMOBILE 7

2 HISTORY AND MAJOR BRANDS

2.1 HISTORY OF MOTORCYCLE 10

2.2 MAJOR BRANDS OF MOTORCYCLE 11

3 DIFFERENT SYSTEMS IN MOTOR CYCLE

3.1 CHASSIS SYSTEM 13

3.1.1 SINGLE CRADLE FRAME 13

3.1.2 DELTA BOX FRAME 14

3.1.3 DIAMOND FRAME 14

3.1.4 TRELLIS FRAME 15

3.1.5 UNDER BONE FRAME 15

3.2 SUSPENSION SYSTEM 16

3.2.1 TELESCOPIC FRONT FORK 16

3.2.2 UPSIDE DOWN TELESCOPIC FORK 17

3.2.3 HOSSACK FRONT SUSPENSION 17

3.2.4 GAS FILLED SHOCK ABSORBER 18

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 3.2.5 MONO SHOCK ABSORBER 18

3.3 BRAKING SYSTEM 19

3.3.1 FRICTION BRAKING SYSTEM 19

3.3.2 COMBI/UNI BRAKING SYSTEM 19

3.3.3 ANTILOCK BRAKING SYSTEM 20

3.4 STERRING SYSTEM 20

3.4.1 TYPES OF STERRING SYSTEM 21

3.5 TRANSMISSIN SYSTEM 21

3.6 WHEELS 22

3.6.1 SPOKE WHEEL 22

3.6.2 ALLOY WHEEL 22

3.6.3 PRESS/STEEL WHEEL 23

3.7 TYRES 23

3.7.1 TYRES IS DISIGIGNATED AS FOLLOWS 23

3.8 ELECTRIC CIRCUIT SYSTEM 24

3.8.1 TYPES OF ELECTRIC CIRCUIT SYSTEM 24

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4 CONCLUSION AND REFERENCES

4.1 CONCLUSION 26

4.2 REFERENCES 26

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 CHAPTER 01
INTRODUCTION

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INTRODUCTION:
1.1 WHAT IS AUTOMOBILE:

Specifically "Auto" means "it self" and refers to something that can operate on it's own with
out any external assistance. "Mobile" means “capable of motion". Either pushed, pulled or
rolled etc. The object is capable of moving easily from one place to another. A self-propelled
passenger vehicle, which is used for land transport and usually consists of four to eight tires &
is powered by an internal combustion engine or an electric motor. The branches of engineering
which deal with the manufacture and technologies of automotive vehicles are known as
automobiles engineering

Automobile

Today automobiles play a majors role in our lives, cannot be imagined without the luxuries of the
modern world. The automobile is used for both passenger and goods transportation, so it serves as
a lifeline for humans. An automobile is a vehicle that is not controlled by humans but controlled
by humans.

There are huge varieties of vehicles in automobiles, for example, cars, buses, trucks, bikes, etc. An
automobile is a self-propelled vehicle that has a power source for its propulsion and is used to
carry passengers and goods on land, such as cars, buses, trucks, etc.

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 CHAPTER 02
HISTORY AND MAJOR BRANDS

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2.1. HISTORY OF MOTORCYCLES:

 Motorcycles have a long history that dates over 100 years and the motorcycle industry has
continued to grow at a tremendous rate with yearly sales of new motorcycles.
 In 1869 Sylvester H. Roper of Roxbury, Massachusetts built a powered machine that could
considered to be the 1st motorcycle

 Roper's machine was quite remarkable and it looked very similar to bicycles but used a
small vertical steam boiler under the seat. The throttle was controlled by twisting the
handlebar forward and backward.
 In 1885 Gottlieb Daimler invented a motorcycle which was recorded as 1st motorcycle in
history with an engine powered by petroleum.

2.2. MAJOR BRANDS OF MOTORCYCLE:

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 Honda’s first full-fledged motorcycle, D-type debuted with an air-cooled 98cc 2 cycle
single cylinder engine. It was first produced at Noguchi plant in Shizuoka.

 Royal Enfield’s 1st v-twin using a 297cc Swiss made motosacoche engine is launched at
the stanley cycle showroom, which has got a numerous completion success.

 Suzuki builds its 1st motorized bicycle, which uses a 36cc, 2-stroke engine clipped to the
frame of conventional bicycle. The power free’s unique double sprocket gear system allows
riders to pedal without engine assistance, or to travel completely under the engine power.

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 CHAPTER 03
DIFFERENT SYSTEMS IN MOTORCYCLES

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3.1 CHASSIS SYSTEM:
All the components of a vehicle except the Engine, Transmission, Electrical & Electronic system
is called Chassis system.

TYPES OF CHASSIS:

 Single cradle frames

 Delta box frames
 Diamond frames
 Trellis frames
 Under bone frames

3.1.1. SINGLE CRADLE FRAMES:

A single cradle frame or single downtube frame resembles the framework of a bicycle. It has a
unique steel tube that goes down to support the engine for a single cradle chassis. It also has a
simple and cost-effective structure. It comprises steel tubes welded together to form a structure
that holds the various components of the motorcycle. In some cases, the engine is attached to the
chassis and works with it, bearing some of the stress. A single cradle chassis, in most cases, would
mention whether the engine is a stressed member of the frame or not.

3.1.2. DELTA BOX FRAMES:

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The Delta box frame gets the name from the shape that is takes. The frame is of a triangular
characteristic and hence the name Delta because of the triangle Greek symbol. The Delta box frame
is made using the controlled flow dye cast aluminum method where the joints in the frame were
made according to the stress points. The points of extreme stress were given thick joints while the
points of low stress were given thin joints. This made it possible to keep the frame of the bike
really light and plus with aluminum as the metal used, it was strong and yet lighter by almost 40%
than the conventional steel frames.

3.1.3. DIAMOND FRAME:

The Diamond frame of the motorcycle gets its name from the diamond shape that the frame has.
Earlier and even today, diamond frames have been used in bicycles. The triangular frame design
is where the diamond frame gets its name.so the same way the motorcycle frame also gets the
triangular frame design with of course some minor changes to suit a motorcycle.

3.1.4. TRELLIS FRAME:

The word ‘trellis‘ means a mesh or framework. It is a type of motor cycle frame. As the name suggests,
the trellis frame contains a number of small straight tubes welded together in numerous
‘triangles’. Manufacturers use either steel or aluminum to make these triangles. This chain of triangles
gives this frame high strength and stiffness required to withstand various forces .

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3.1.5. UNDER BONE FRAME:
An under bone is a type of motor cycle that uses structural tube framing with an overlay of plastic
or non-structural body panels and contrasts with monocque or unibody designs where pressed steel
serves both as the vehicle's structure and bodywork. Outside Asia, the term under bone is
commonly misunderstood to refer to any lightweight motorcycle that uses the construction type,
known colloquially. An under bone motorcycle may share its fuel tank position and tube framing,
along with fitted bodywork and splash guards with a scooter while the wheel dimensions, engine
layouts, and power transmission are similar with conventional motorcycles.

3.2. SUSPENSION SYSTEM:

 The principle of Suspension system works by converting kinetic energy(moment) into
thermal energy(heat) by means of Hydraulic fluid.
 In motorcycle suspension system serves as dual purpose: Contributing to the vehicles
handling and braking, and providing safety, comfort by keeping the riders comfortably
isolated from road shocks, bumps and vibrations.

Typical motorcycle has front suspension and rear suspension.

 Front suspension has a pair of fork tubes

 Rear suspension has a swingarm with 1 or 2 shock absorbers.

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3.2.1TELESCOPIC FRONT FORK:
Telescopic suspension is a type of hydraulic suspension system with internal coils. Telescopic
suspension is mostly used for motorcycles, where it is highly successful due to its weight and
capability to absorb. The main purpose of the suspension is to resist the unnecessary motion of the
spring and It provides a very comfortable ride. It also provides stability while graduating.
Telescopic suspension is one tube that slides inside another one. Motorcycle front forks and auto
shock absorbs are telescopic suspensions. It would be rare to hear call car shock absorber
telephonic suspensions.

3.2.2. UPSIDE DOWN TELESCOPIC FORK:

The front suspension systems known as upside-down forks or interned forks have outer, a stronger
tube attached to a yoke, whereas the lightweight inner sliding rod is attached towards the front
axle. The heavier section of the frame is kept closer to the bike's frame, while the unspring weight
of the tyre is decreased. As a result of the decreased friction, the front wheel has a higher capacity
to travel over bumps.

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3.2.3. HOSSACK FRONT SUSPENSION:
Norman Hossack decided to show us what a trellis frame Ducati could look like by engineering a
front suspension with trellis uprights. You get all of the performance advantages of a hossack
suspension plus lighter weight. One glance at the finished product and the visual symmetry of the
combination makes you wonder why Ducati didn’t build it like this to begin.

3.2.4. GAS FILLED SHOCK ABSORBER:

The gas filled shock-ups can be easily differentiated by ‘Canister’ attached to the conventional
spring loaded shock absorber. It is this Canister which holds the gas inside, it is mostly Nitrogen
gas used in these cans and that is the reason why it is also known as ‘Nitrox’ dampers. Before we
go ahead with the details of the topic it is mandatory to check how a shock absorber (conventional)
works.

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3.2.5. MONO SHOCK ABSORBER
The use of a single shock means using a single valve, which exerts pressure equally unlike twin
shocks. To add to this, the piston in a mono shock is much wider than the one found on twin-
shock absorbers. In effect, mono shocks offer better and more precise damping, which results in
better handling and stability.

3.3. BRAKING SYSTEM:

A brake is a mechanical device that inhibits motion by absorbing energy from a moving system. It
is used for slowing down or stopping the moving vehicle is accomplished by means of friction.

TYPES OF BRAKES:
 Frictional braking system
 Combi/Uni braking system
 Antilock braking system

3.3.1. FRICTION BRAKING SYSTEM:

Most popular type of brake used in vehicles . Its function is, a friction brake uses friction between
a moving and stationary part of brake, which are pressed together during braking. Friction is the
force opposing relative moment of two surfaces in contact.

Types:

1. Disc brakes.

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2. Drum brakes.

3.3.2. COMBI/UNI BRAKING SYSTEM:

It is the most efficient way of braking which applies the front and rear brakes simultaneously using
single lever. It reduces the braking distance and improves stability while braking.

3.3.3. ANTILOCK BRAKING SYSTEM:

ABS is used to avoid the locking of wheel which tends the vehicle to skid in certain situations.
ABS has electronic control unit(ECU) which supplies an equal amount of braking force to each
wheel depending upon road conditions.

3.4. STERRING SYSTEM:

 The system which helps to turn the vehicle as per rider wish is called the steering system.
 A steering system of a motorcycle includes a head pipe, steering arm, top bridge, bottom
bridge, front fork and steering handlebar.

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  Caster angle and Trail distance must be considered for achieving perfect steering and these
values may vary depending on the design of the vehicle.

Caster angle: It is the angle of a motorcycle’s steering head of the frame.

Trail distance: It is the distance (measured in inch or mm) between the point of the front wheels
contact with the ground and a line drawn through the axis of the steering head.

3.4.1. STERRING SYSTEM:

 Telescopic front fork system
 Girder front fork system
 Hub center steering system

3.5. TRANSMISSION SYSTEM:

It is used to transmit the engine power to the wheels in such a manner where minimum power loss
and maximum efficiency can be delivered.

There are 3 types of transmission system:

 Chain type:

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  Belt type:

 Shaft type:

3.6. WHEEL:
A wheel is a circular block of a hard durable material whose centre has been bored a circular hole
through which an axle bearing is placed, about which the wheel rotates when a moment is applied
by torque to the wheel about its axis

WHEELS ARE DIVIDED INTO 3 TYPES:

3.6.1 SPOKE WHEEL: These are more durable, hence widely used on off-road bikes,
enduros, scrambles. Bikes like Hero Xpluse200,Hero Honda, Royal Enfield Himalayan uses
spoke wheels.

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3.6.2 ALLOY WHEEL: These wheels are extensively used because it is more rigid compare
to spoke wheels, which helps to endure high amount of horsepower and torque. As a result these
bikes are more stable at high speeds. This type of wheels are mostly seen in performance oriented
bikes.

3.6.3 PRESSED / STEEL WHEEL: These are more durable, significantly stronger than
alloy wheels in any conditions. Cracking and bending of steel wheel requires a large amount of
force. As long as you maintain the layer of paint on your wheel, it will not get rust. Advantage of
steel wheel is, it is cheaper than other wheels

3.7 TYRES:

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  A tyre is a ring shaped component that surrounded by wheels rim to transfer a vehicle load
from the axle through the wheel to the ground and to provide traction on the surface of the
road.
 Tyre’s are pneumatically inflated structure which provide flexible cushion that absorbs
shock as the tyre rolls over rough surface.

3.7.1TYRE IS DESIGNATED AS FOLLOWS:

1. Cross Section Width: The 1st three numbers, in this case 195, refers to the section-width of
the tyre. This is the measurement in mm from the tyre’s inner sidewall to outer sidewall.

2. Aspect Ratio: The aspect ratio or profile refers to the height of the sidewall as a percentage
of the section width, in this case 55 means the height is equal to 55% of the 195mm width.

3. Construction Type: The letter R means the tyre as a radial construction. Almost all new car
tyre’s are radial.

4. Rim Diameter: The number to the right of the construction type is the Rim diameter measured
in inch in this case it is 16 inch wheel.

5. Load Index: The number is load index that means the maximum load in KG that the tyre can
carry.
6. Speed Index: The final number is the speed index i.e. the maximum speed that the vehicle
can travel.

3.8. ELECTRIC CIRCUIT SYSTEM:

A charging circuit supplies the battery via the alternator and voltage regulator / rectifier. An
ignition circuit supplies the ignition unit, ignition coils and spark plugs. A lighting circuit supplies
power to the headlight, instruments and tail light.

3.8.1. TYPES OF ELECTRIC CIRCUIT SYSTEM:

 Lightning circuit

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 Signaling circuit
 Ignition circuit
 Starting circuit
 Charging circuit

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 CHAPTER 04
CONCLUSION AND REFERENCES

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4.1 CONCLUSION:
In recent times great boom is visualizing in Indian automobile sector. Due to competition in two
wheeler industries Advance techniques are adopted in newly launching vehicles. Different
companies such as hero Honda, Yamaha, and Bajaj introduce new techniques in their new product .

4.2 REFERENCES:
 "Honda Worldwide | Technology Close-up". World.honda.com
 Effectiveness of ABS and Vehicle Stability Control Systems" (PDF). Royal Automobile
Club of Victoria, First Automotive Anti-lock Brake System (ABS) gmheritagecenter.com
 "ABS 'should be compulsory on new motorcycles by 2015' - Latest Transport News -
Transport News - TRL News Hub".
 bikeadvice.in › anti-lock-braking-system-abs
 http://www.tezu.ernet.in/sae/Download/transmissi on.pdf
 A Textbook of Automobile Engineering by R.K. Rajput
 [7] Automobile Engineering (Vol. I and II) by Dr. Kripal Singh

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