All Terrain Vehicle

Conquer Every Terrain

Project: All Terrain Vehicle

Project duration: 1 Year

Role: Team Captain & Design Lead

Worked on:

Design & Manufacturing calculations
Mechanical design & assembly of parts in all domains
Ergonomics & Aesthetics
CNC Manufacturing
Testing

INTRODUCTION

The All-Terrain Vehicle (ATV) project for BAJA 2019 is an exciting venture undertaken by our team of enthusiastic and skilled engineering students. The project aims to design, manufacture, and compete with a robust and high-performance ATV in the prestigious BAJA SAE (Society of Automotive Engineers) competition. Our vehicle was tailored to withstand challenging terrains, display exceptional off-road capabilities, and showcase innovative engineering solutions.

For Chassis, Chromoly alloy, also known as 4130 steel, was chosen for its excellent strength-to-weight ratio and exceptional mechanical properties. It offers a higher tensile strength and yield strength compared to standard steel, making it ideal for off-road applications where durability and lightweight construction are essential.

Additional cross bracing and strategically placed gussets were incorporated into the chassis design. These elements further reinforce critical stress points, improving the overall structural integrity of the vehicle.

By leveraging a mannequin model within the CAD software, precise and accurate fine-tuning of driver ergonomics was achieved. Detailed simulations and iterative adjustments allowed for the perfect alignment of controls and seating. This human-centric approach resulted in an all-terrain vehicle that prioritized driver comfort, safety, and optimal performance.

FEA is then used to simulate the stress distribution, deflection, and structural integrity of the chassis under various loads and boundary conditions. This iterative process helped identify stress concentrations and weak areas, leading to improvements in the design to handle the rigorous demands of off-road conditions.

Similar approach was followed for the design of all the other components of ATV.

In the pursuit of creating a high-performance and robust wheel assembly, our team employed advanced structural analysis and topology optimization techniques. This innovative approach enabled us to refine the design of crucial components, including the hub, knuckle, and brake disc, resulting in an optimized wheel assembly that met stringent performance criteria while minimizing weight and material usage.

Utilizing structural analysis, we subjected the wheel assembly components to simulated loading scenarios, evaluating stress distribution and deformation under various operating conditions. This comprehensive evaluation allowed us to identify potential weak points and areas of stress concentration, guiding us towards targeted improvements.

Through the unwavering dedication of our incredible team, we achieved a significant milestone by winning the award for the Sled Pull Event at SAE BAJA 2019. The event truly put our ATV’s capabilities to the test, demanding immense pulling force, optimal weight distribution, and superior traction. Our victory stands as a testament to our team’s collaborative effort and relentless pursuit of perfection, enabling us to conquer the challenging course with determination and hard work.