TEAM DUNE RIDERS

C.G.Patel.Institute Of Technology,Bardoli,Gujarat
Raise the bar!!
ENDURED
TESTED
TRIED
Dummy
Product Development Cycle
Using creo 2.0 for designing
And ANSYS(WORKBENCH) 11 for FEA report.
Wireframe view
3D view
Design consideration

Design specification Proposed Actual
Roll cage length 108 100
Roll cage breadth 64 63
Wheel base - 71
Track width - Front-
57
Rear-63
Total height 52
Ground clearance 8
3D- Side view
3D-Top view
Subject Property
Material ST-52
Carbon% 0.20%
Density 7.8 *10^3
kg/m^3
Yield strength 355 MPa
Young's modulus 210 GPa
Poisons ratio 0.30
Roll cage weight 56kg
Total weight of the
vehicle
320 kg(appr)
Material consideration
3D-Front view
FI DEFORMATION-16 mm
FI STRESS-256 MPa
TORSIONAL DEFORMATION-88 mm TORSIONAL STRESS-206.84 MPa
Bump deformation-104 mm BUMP STRESS-282.9 MPa Side deformation-17 mm Side stress-825 MPa
With ample driver cabin space, driver from our
ATV can come out of the vehicle in less then 5s.
Dimensions in the driver cabin are:



Factors of driver cabin Dimension
Length 48
Breadth(front) 26
Breadth(rear) 36
Height(from drivers seat to top) 48
Drivers leg space 20
Wind shield inclination 40deg
Safety equipments
1. Kill switch- reliable pulsar kill
switches are been used near
drivers cabin and also at the rear
side of the vehicle
2. Fire extinguisher for emergency
fire catching both in front side and
the rear side of the ATV
3. Reliable roll cage material and its
design adds to better safety of the
driver and also creates less of
vibrations.
4. Polyethylene pad cover on roll
cage adds to safety of the driver in
case crash or sudden hit.

Driver cockpit with maximum
vision
Driver seating
position
Configuration of suspension We are using
Honda suspension for front and rear. With
arms available from the market.
Parameters Front Rear
Type Double wishbone McPherson
Wire diameter 50mm 50mm
Roll center
Coil diameter 6.28 inch 6.28 inch
Number of coils 4 4
Parameter Front Rear
Caster -2.2 -2
Camber 2 0
Pictures of suspension and
arms.
Double wishbone
suspension system

Fully adjustable lock-to-lock travel
Adjustable steering rake angle.
Detachable steering wheel.
Quick ingress and egress.
With rack and pinion of Maruti 800 which is more
efficient:


Steer wheel travel 540deg
Rack travel 120mm
Steering ratio 15.1:1
Minimum turning radius 3.86
Inner wheel turning angle 26.56
Outer wheel turning angle 20.36
Picture of the joint
Steering
System
Rack
&
Pinio
n
Worm
&
Sector
Worm
&
Roller
Recirculating
Ball screw
Cam &
Lever
Cost 4 3 4 3 3
Availability 4 3 3 2 4
Weight 4 3 3 2 3
Efficiency 3 3 3 4 3
Total 15 12 13 11 13
Source-automobile engineering by KM
GUPTA
For more efficient brakes we are using 4
wheeled disk brakes with single master
cylinder
Stopping distance for the braking system is
4.1m


Component name dimensio
n
Disc diameter 215.2 mm
Brake disc thickness 10 mm
Minimum thickness 9 mm
Centering diameter 86 mm
Number of holes 4
Thread size M10*1.25
Pitch circle 102 mm
Electrical circuit
Mainly our ATV consists electrical parts like:
1)Kill switch(front and rear) 3)Tail light, Head light, side light
2)Fire extinguisher(front and rear) 4)horn
As a set standard for the completion we are using Mahindra
xalfa champion transaxle for the transmitting power to wheels.
Starter linkage mechanism has been used for linking clutch
pedal with the gear box
With four forward and one reverse gear box having top speed
of 56 km/hr.
Aluminum glass covered clutch plate eases the gear shifting
and also asbestos friction plate increases its strength.

Shorter and wider Contact forces
Less traction and good road grip
Larger cornering forces
Puncture resistant
Front- : 22 8 10
Rear-: : 22 8 10

Sr no, Gear ratios Speed
1 31 12.95 km/hr
2 18.7 21.38 km/hr
3 11 36.86 km/hr
4 7.1 56.35 km/hr
Team distribution


team division member name
finance harsh joshi
kshitish Trivedi
sponsorship jay kalavadia
sanket patel
meet mistry
purchasing Ravi Solanki
Karan kanani
shivshankar yadav
quality anand singh
Rahul Sharma
bhavin Patel
driver sanket patel
Bhardwaj mahida
desgin Mahesh Sharma
denish mevawala
jigar desai
fabrication Ganesh jadhav
dipen desai
manoj Sharma
bhishma desai
Kevin b
ronak Aggarwal
raj Patel
parth desai
harry Thacker
sagar shah
Auto vehicle test lane.
Decarburizing machine.
Wheel alignment and Wheel Balancer.
Ultrasonic spark plug cleaner.
Production lathes, grinding, drilling and Milling machines.
Spot, Seam, Arc, MIG welding machines.
Two post hoist.
Manually operated bending machine.
Various types of presses.
Grease pump.
Auto scan tool.
Workshop Pneumatic tools.
Five gas analyzer.
Software's available are Pro-E, Autodesk Inventor, AutoCAD.
Universal testing machine.


Test detail Test requirements Acceptance standard Department Source-college Source-external
Steel material
verification
Universal testing machine Rulebook & design Design+fabrication YES
Speed test Chassis dynamometer Rulebook standard Design+fabrication YES
Fuel consumption Hydraulic dynamometer Suitable standard Fabrication YES
Test of weld joints NDT(powder testing) Rulebook criteria Fabrication NO
Safety check Vehicle Rulebook criteria Design+driver YES
Electrical check Vehicle Rulebook criteria Electrical department YES
Brake test Vehicle track Required standards Brake department YES
Suspension testing UTM+vehicle Rulebook specification Suspension department YES
Stability of vehicle Chassis dynamometer Rulebook specification Fabrication+design NO
Stopping distance Vehicle/design/track Rulebook criteria Brake+design YES
DCBS testing Vehicle/design Calculated standard Brake+fabrication
Vehicle vibration Chassis dynamometer Rulebook specification Desgin+fabrication NO
Turning radius Vehicle+track 3.75m Steering department YES
Wheel alignment &
balancing
Vehicle+alignment+balancing
machine
Suitable standards Suspension department YES
With lot of thinking we came to conclusion with two innovative
idea:
Dual caliber independent locking system(DCILS):
With the use of double caliber in braking system we
intend to decrease the stopping distance of our vehicle
drastically.
Also by using solenoid valve we will control the
fluid supply to different brakes on the wheel, with the help
switches on gear leaver. For example if we control the front two
brakes and the rear left brake, we can drift the rear right wheel
and take out from the struck region in the track.

Knuckle for
Dual caliber
brake
Knuckle deformation-0.006 mm
Sr
no.
Item Projected
cost
Sub total Estimated
weight
Retail
price
Labour
charge
1 Engine 25000 1000 26000 25kg
2 Transmissi
on
Rs-18000 500 18500 25kg
3 Brake Rs-32000 400 32400 20kg
4 Safety
(including
Driver)
Rs-19,247 200 19447 90kg
5 Steering
assembly
Rs-7250 500 7750 10kg
6 Roll cage
and body
parts
Rs-17800 3000 20800 65kg
7 Suspension
system
Rs-19500 1000 20500 50kg
8 Tires Rs-25000 500 25500 25kg
9 Electrical Rs-8000 500 8500 10kg
10 Miscellane
ous
Rs-5000 1000 6000
Total Rs-1,54,297 Rs-10600 Rs-1,64,897 320kg
Due to rapid growth of our college,
BAJA completion is 80% financed by
our college.
Rest of the financing would be taken
by component sharing methodology
from automobile vendors.
Marketing of the vehicle will be
based on original equipment
manufacturing.
Maximum effort will be given during
fabrication for customer satisfaction
in case of vehicle breakdown.
14%
10%
18%
10% 4%
11%
11%
14%
5%
3%
0%
Total cost price
Engine Transmission brake safety equipment
steering assembley roll cage and body syspension system tires
electrical miscellaneous
Item Potential failure
mode
Potential effect
of failure
Potential
mechanism of
failure
Current design
controls
Recommended actions Actions taken sev occ Det

Tyre puncture Insertion of
pointed things
inside
Wear of tyre surface Tyre general
durability
-
Change of tyre /else
opt for tubeless tyre
Tyre changed 9 8 1

gear box Improper meshing of
gears
rubbing of teeth
and breaking of
teeth
Insufficient
lubrication
Lubrication needed Lubrication done 5 4 1
Fuel consumption Increased delivery of
fuel and increased
deposition of carbon
on spark plug or fuel
injector
Increased
deposition of
carbon over
spark plug or
fuel injector
Carbon deposition Cleaning of spark
plug or fuel injector
Cleaned spark plug
as well as fuel
injector
4 4 1
suspension Spring Stiffness of
spring reduced
Because of much
used application
More stiffness
and durability
needed
Change of spring Spring changed 7 6 8
Arm Breaking of arm Unbalanced load
acting on arm
Accurate
dimension and
design
Change of arms Arms changed 8 3 2
Electrical system Not working of
headlamps and brake
light
Blowoff of lamp Because of loose
connection of
electrical system
Correction of wiring Wires replaced as
well as proper
arranged
5 6 2
brake Wear of brake
pad,improper
arrangment of brake
system
Leakage of fluid
Wear of brake
pad
Due to high friction
between brake pad
drum
Change of brake pad Brake pad changed 8 6 4