MINOR PROJECT

Design and Fabrication of Off-Road Electric Bike

for Single Occupant
SUBMITTED BY:-
Anjali Naagar - 44215603617
Mukul Kumar Nim - 00415607418
Prabhakar - 00515607418 GUIDED BY :- Mr. Ankit Saxena
Shivam Kumar - 00815607418 (Assistant Professor,Department of
Tanweer Faisal - 00915607418 Mechanical & Automation
Varun - 01015607418 Engineering)
Ankit Kumar - 40215607418
Keshav Kumar Jha - 90115607418
 OBJECTIVE
The objective of this project is the design and fabrication of an off-road electric bike for single occupant.

ABSTRACT
E-bikes are electric bikes which are driven by the use of electricity as the source of fuel. E-bikes
are opted for its eco-friendliness and cost-effectiveness for transportation. In the present study,
optimum design for an electric bike was modeled and analyzed for stress and failure rate for
commercial purpose. Frame is backbone of the bike; it supports and holds the whole load. The
main objective of the paper was to design and fabricate a light weight still strong, safe, and
economical than the conventional ones. The material used is of AISI standard. The analysis
comprised of static simulations and linear dynamic analysis for sudden impacts of all the
components in the frame. It could be concluded that the design of the e-bikes was so fabricated
that it could withstand impacts.
 INTRODUCTION
The rise of demand and constantly increasing cost of petrol and
diesel has been ruling India for ages; society needed a non-
negotiable solution especially in India. Transportation is very
important and in order to augment it, people started seeking
transportation by different means of energy. Electric vehicles gave a
breakthrough solution to satisfy the needs required thereby it
started to flourish, by overcoming the hindrance. Electric Bikes are
two wheeler vehicles which uses electricity as the source of fuel.
Electric motorcycles are noiseless, pollution free, zero-emission,
and electrically driven. The operation and speed are controlled by
the battery. To extend the variety of e-bikes and improve the
production. The usage of electric bikes has turned out to be a
solution for reducing pollution to a larger extent. To burgeon the sale
of e-bikes it needs to be enhanced in quality, hence in the present
study the e-bikes are designed with frame which is light in weight
when compared to conventional bikes for the purpose of efficiency.
 DESIGN CONSIDERATIONS
While designing a frame for an electric motorcycle, it is very important to take
into consideration the type of frame structure that will be appropriate to
mount the components required for electric mobility such as the motor,
battery pack, battery charger, etc. As well as the essential components and
systems that are present in a conventional motorcycle. Following are the
various types of motorcycle frames that are in practical use:

● Spine or backbone frame: it comprises of a large diameter tube which

acts as the spine of the bike upon which the components are hung thus
acting like a core structure.
● Single cradle frame: it consists of a single top tube and a single down
tube that runs from steering head to swingarm pivot thus forming a loop
on which various components are mounted.
● Full-duplex cradle frame: it consists of a single top tube
and two down tubes that run from steering head to
swingarm pivot thus forming a loop on which various
components are mounted.

● Perimeter frame: it consists of two box-section beams

joining the steering head with the swingarm in the shortest
possible length for maximum rigidity and stiffness.

● Monocoque frame: it comprises of a structure where

loads are supported through its external skin which acts as
its core for component mountings.
● Trellis frame: it consists of several short steel or aluminium tubes welded
together into a series of triangles which provide the frame with strength and
stiffness.

EXPLODED VIEW OF TRELLIS FRAME

 WHY WE SELECT TRELLIS FRAME?

The trellis frame is the lightest frame and yet provides high rigidity due to the
triangulations provided by the tubes of the frame. The trellis frame thus, has the
highest strength to weight ratio among all frame types. The tubes of the trellis can
accommodate components of larger size which also perform structural duties
themselves thus providing increased strength and rigidity. Trellis frame provides better
centralization and lowering of the overall vehicle weight. The main aim was to reduce
the weight, centralize the weight and lower the weight of the frame.
GEOMETRY OF When developing a motorcycle chassis one of the most
remarkable points is the design of its geometry. There are
THE CHASSIS some characteristic measures in a motorcycle that determine
its handling, responsiveness, manoeuvrability and stability.
Coming up next, a presentation and short explanation of the
main measures of a motorcycle is done:
● Wheelbase: it's the distance between the contact points of the tires on the road. Its value
varies from 1200mm in small scooters to 1600mm in customs and touring motorbikes.
The increase of the wheelbase implies: ·A higher flexional and torsion deformability of the
frame. ·A higher turning radius, which worsens the manoeuvrability. ·A higher directional
stability at high speeds.;

● Caster angle: it's the angle between the vertical axis and the rotation axis of the fork. It
affects to the inclination of the wheel that happens during steering, which is directly
related to the hardness of the direction and its responsiveness; normal values of the
caster angle are between 21º in sports motorcycles and 30º for touring motorcycles.

● Trail: it's the distance between the contact point of the front wheel and the intersection
point of the steering head axis with the road measured in the ground plane. It has a deep
relationship with the caster angle because the change of one of these measures can't be
done without the change of the other. It affects to the stability of the front end in straight
line conditions: the higher the trail is, the higher is the returning moment of the steering
that self-aligns the wheel. Normal values of the trail vary between 80mm to 120mm.
 SIMULATION
The different simulations that have been done.
Simulations are an essential part of the design
of the chassis because they enable the
chance to guarantee the mechanical
properties before building up all the structure
and allow the optimization of the design; for
this reason, they appear to be one of the trunk
parts of this project. For the automotive is one
of world's most cutting-edge industries,
simulations have been profoundly developed
for these applications and the great part of the
simulation process has become standardized
in order to have reliable results and
conclusions.
 ENVIRONMENTAL IMPACT
 Electric mobility is arguably one of the major symbols of the green movement. Probably
the reason is that this particular part of the automotive industry has to fight directly
against the refineries and fossil fuel producers to survive. Considering all the global
interests and the great amount of money that fuel moves, the fact that the electric
mobility exists is already a win and shows that the world is beginning to understand the
effects of pollution. Every day, the concept of carbon footprint takes more importance in
the industry, and companies and also costumers want to make sure that products are
not damaging the environment.

 Neglecting the effect of the carbon footprint, there is certainly one factor of electric
vehicles that has an adverse effect on the environment: batteries. The kind of batteries
that uses the most part of electric vehicles nowadays contain hazard materials for the
earth and the environment and, most of the times, they cannot be recycled. This
constitutes the main downside of electric vehicles referring to the environment keeping
and is one of the main reasons for the investigation on the hydrogen cell.
 CONCLUSION
The final result of this project has been very favorable, for the objectives that have been
put in the beginning have been achieved.
To design an electric bike which is lightweight and can run on all kinds of tracks.To
make an electric bike with a maximum speed of 80 km/h. To make an electric
motorcycle with range of 70 km in full charging. To make environment friendly vehicle.
 REFERENCE
● COSSALTER, Motorcycle dynamics, second edition,
ISBN: 978-1-4303-0861-4
● FOALE, Motorcycle handling and chassis design,
first edition, E-book copy
● ASHBY, Materials selection in mechanical design,
fourth edition
● CHEVALIER, Dibujo industrial