Manuacturing and Testing of a Single Seater Off-Road Car.

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

Manuacturing and Testing of a Single Seater Off-Road Car.

Rachit Kunder1, Bharat Sonagara2

1,2 VIVA Institute of Technology Mechanical Department, Mumbai, India ***

Theobjectiveofthestudyistofabricatesafestvehiclefora driver.Therollcagehasbeenfabricatedinaccordancewith SAEBAJArulebook.3DAssemblyofwholevehicle&Line model of the roll cage is modeled in SOLIDWORKS 2018. Different processes are used to manufacture different componentswithaviewtocutbackcostandachieveproper tolerancesatsametime.

INTRODUCTION

AnOff roadcarorAll Terrainvehicle(ATV)isessentially aLandbasedvehiclecapableofreachingremoteareaswhere normalcars/bikescannotreach.ATVhasasignificantlygood range of applications nowadays like in Military, Forest departments,Farming,etc.Theprojectistomanufacturean ATVwithdifferentmachiningprocess,andmakingtheentire assemblyofanAll terrainvehicle.

A. ROLLCAGE

1. PIPE MATERIAL SELECTION

Thematerial usedforthevehicleroll cageisAISI4130 (chrome molysteel)i.e.chromiummolybdenumalloysteel, on the basis of comparative study on parameters like materialavailability,Cost,WeightandPhysicalparameters. Aftercomparingthesefollowingparameterswithothersteel grades like AISI 1018 and AISI 1020, AISI 4130 is comparatively best among them with the structure, maintainingtheIntegrityoftheSpecifications

2. PIPE SIZE SELECTION

Inaviewofgainingsignificantresultsinweightreduction, some changes were incorporated in pipe sizing. For the currentcarthediameterofthepipewasselectedconsidering theequivalencycalculationsasperrules.

TABLEI

Pipe Sizing (OD mm x thickness mm)

Primary 29.2 x 1.65

Secondary 25.4 x 1

3. MANUFACTURING

ThemanufacturingofRollcageincludesthreeprocesses thatispipebending,pipenotchingandwelding.

a. PIPE BENDING

Pipeisbentforeasymanufacturingofrollcageandavoid unnecessaryweldingofpipewhereverstrongstructureisn’t necessary.

b. FIXTURES

To avoid unnecessary movement of pipe structure and accurateassemblingofeachmemberflexandmetalfixtures wereused.

c. PIPE NOTCHING

PipeNotchingisprovidedforcorrectseatingofrollcage pipesenablingaccurateassemblyandweldingofrollcage.

D. ARGON WELDING

Argon welding is employed for joining of roll cage membersorpipessinceitprovidesstrengthtonodesofpipes andavoidanyfailure

MANUFACTURING

GearboxwasmanufacturedfromAluminumalloy6061 T6 block using VMC,other processes involvedare turning, gearcuttinganddrillingforGears.

a. VMC MILLING

Endmillingandfacemillingprocesshavebeenusedfor cuttingprocessofgearboxcasing.Around4hourswastaken tocompletetheseprocessesandasingleblockwasusedfor both sides of casing to reduce the machining as well as materialcost.

B. POWER TRAIN

Theprimeobjectiveofthepowertrainsystemistoattaina goodvelocitywithhighefficiencypowertransmission.The powertrainsystemmustbeabletodelivermaximumtorque fromtheenginetothewheel.Hence,continuouslyvariable transmission(CVT)ischosentoattainmaximumtorque.

InadditiontoCVTitcontainstwostagereductiongearbox which is created from the Aluminum for a light weight housingofgears.

1. GEARBOX CASING

Thegearboxcasingisrequiredforoptimumoperationof the gear drives. It provides ample lubrication, protection from environmental element and proper gear orientation. ThematerialusedforgearboxcasingisAluminum6061 T6 considering its light weight, machinability and heat dissipationproperty.ItismachinedonCNCmillingmachine forproperfittingandcompactness.

2. DRIVE SHAFT

Thedriveshaftiscustomizedtosuittherequirementof thevehicle.BoththeendofthehalfshaftcontainsCVjoint. One end is connected with spool and another end is connectedtowheel.Thedriveshaftdiameterisselectedafter calculationandconsideringthemaximumoperatingtorqueat spoolend.

ONVENTIONAL TURNING

ConventionalTurningonlathemachineofgearsandshaft wasperformedtogetrequireddiameterandfacingoperation forlengthofshaft/thicknessofgears.

c. GEAR CUTTING

Afterturninggearcuttingandsplinecuttingisdonetoget requiredgearprofile.

d. DRILLING

Drillingisdoneforremovalofunnecessaryweightform gears

e. TAPPING

Tappingisdoneforfasteningofgearboxcasingandalso forthemountingofrearbrakecaliper.

f. CASE HARDENING

Gearshavebeencasehardenedtointherangeof30 45 HRCupto2mmthickness.

C. STEERING

Thedesignaimofthesteeringteamwastoensuresmooth maneuveringofvehicleduringCorners.Inordertoachieve theratioofvehiclewheelbasetotrackwidthiskeptcloseto 1:1. Steering system hard points were first determined by consideringtheclearanceandergonomics.

EN 24steelwasselectedasmaterialforrackandpinion of the steering. For housing of rack and pinion, nylon 6 materialforcasingisused,asitislightinweightandeasily machinable.SteeringarmismadeofP 40steelforstrength anddurabilityofwheelassembly

1. MANUFACTURING

Different processes were used for complete manufacturingofsteeringsystem.

a.

CONVENTIONAL LATHE

Togetrequireddimensionsofrack,pinion,tierodsand columnlathewasusedfortheprocessesofturningfacingetc.

b. TAPPING

Tappingwasdoneonbothsidesofrackforassemblyof Heimandballjoints.

c. GEAR CUTING

Gear cutting and spline cutting is done to get required gear.

d. CASE HARDENING

Gearshavebeencasehardenedtointherangeof30 45 HRCupto2mmthickness.

e. VMC MACHINING

Endmillingandfacemillingprocesshavebeenusedfor cuttingprocessofSteeringcasing.Around1hourwastaken tocompletetheseprocessesandasingleblockwasusedto reducethemachiningaswellasmaterialcost.

f. LASER CUTTING

Lasercuttingprocesswasusedforcuttingof4mmsteel sheetformountingbrackets.

D. SUSPENSION SYSTEM

1. PIPE SIZE SELECTION

Diameter of the pipe was considered according to the equivalencydesigncalculations.

TABLEII

2. MANUFACTURING

Themanufacturingofsuspensionarmsincludesmajorly two processes that is pipe notching and welding after preparing appropriate fixtures for proper seating of pipe members.

a. FIXTURES

To avoid unnecessary movement of pipe structure and accurateassemblingofeverymemberflexandmetalfixtures wereused.

b. PIPE NOTCHING

PipeNotchingisdoneforproperseatingofsuspension armsforproperassemblyandweldingofpipes.

E. HUBS & UPRIGHTS

CustomdesignuprightsandhubswereusedforStrength anddurabilityofwheelassembly.P 40steelisselectedfor highimpactloadsandhighdurability.

RGON WELDING

Argonweldingisusedforjoiningofsuspensionarmsor pipessinceitprovidesstrengthtonodesofpipesandavoid anyfailure.

1. MANUFACTURING

Different processes were used for complete manufacturingofWheelassemblycomponents.

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

a. CONVENTIONAL LATHE

Togetrequireddimensionsofhubandwheelaxlelathe wasusedfortheprocessesofturningfacingetc

b. VMC MILLING

Endmillingandfacemillingprocesshavebeenusedfor cuttingprocessofhubandknuckle.Around6hoursoverall wastakentocompletetheseprocesses.Aroundbarwasused forhubsandplatewasusedtoreducethemachiningaswell asmaterialcost.

F. BRAKES

Theobjectivebehindthebrakingsystemistolockallthe fourwheelsdynamicallysoastotoensurethesafetyofthe driverandmaneuverabilityofthevehicle.

Brake rotors are custom manufactured to achieve the required output and to achieve design requirement for reductionofweight.

1. BRAKE ROTOR

Inordertoreducetheweight,slotteddesignofrotorwas selected.Accordingtothosecalculationseffectiveradiusof rotorwasdecided.

MATERIAL SELECTION

Theparametersconsideredwhileselectingmaterialfor brakerotoraremachinability,frictionalproperty,hardness and resistance against rusting and wear etc. accordingly, SS304 is selected complying with market availability and cost.

2. PEDALS

Overhangingassemblywasselectedconsideringdriver comfortandpositionofsteeringsystem.

3. MANUFACTURING

a. LASER CUTTING

Lasercuttingwasusedforcuttingofbrakediscandbrake pedal.

G. FULL CAR ASSEMBLY

Stepbystepassemblingofsub assemblywascarriedout

AssemblingofB&Sengine,GearboxandCVT

Assemblingofbodypanelsandcovers.

AssemblingofwishbonesandFoxShocks.

Assemblingofuprights,brakerotorsandhubs

Assemblingofpedalassembly.

Assemblingofsteeringsystem.

Assemblingofseatanddriversafetyperipherals.

H.

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p ISSN: 2395 0072

2. PERFORMANCE/TRACK TESTING

VarioustracktestsincludeManeuverability,Suspension and Traction, Acceleration, Hill climb, Sled pull and Endurancetestsareperformedonvariousterrains.

a. Maneuverabilitytestisdonetocheckcar’sturning abilityatsharpcorners.

b. Suspension and traction tests are done to check abilityofcartowithstandworstofterrain.

c. Acceleration tests are done to check speed and accelerationofcar.

d. Sled pull is done to check power and torque of gearboxandtransmissionsystem.

e. Hill climb is done to test car’s ability to overcome steepslopes.

f. Endurancetestisdoneforrunningcaratleast500km to check whether the car can withstand rough terrainsinfullspeedwithoutanybreakdown.

2. ESTHETICS

Vinylwasprintedandpastedonbodypanelstoaddtoits aestheticview.

I. PAINTING, AESTHETICS AND FINALIZATION.

1. PAINTING

PaintingofCarwasdoneusingsimplespraypaintcans withDFT(Dryfilmthickness)rangefrom15 20microns.

3.FINAL PRODUCT

FRP (ie. Fibre reinforced plastic) seat, Driver safety restraints, Engine Kill Switches, Fire extinguishers are alsoinstalledinthecar.

J. RESULT AND DISCUSSION

Fully functional All terrain vehicle has been manufactured, assembled and tested successfully. The basic test results prove that car is safe for driver with respecttomaterialsused.Thetracktestsprovethatcar hasspeedof52kmph,canmaneuverthroughcornersas tightas0turningradius,climbshillwithgradeabilityof 68%, stops within 4m patch when brakes applied at a speedof52kmphandcaneasilyendurefor4hoursof roughterrainatmaxspeed.

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056

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K. CONCLUSION

Thechosendesignwasthesafestandthemostreliable car for any long terrain. All the parameters like safety, cost, performance, aesthetics, reliability, durability, standard dimensions and material were also taken in considerationonthesametime.Thevehiclewassafeinall aspectsandconformswithsafetyrulesspecifiedinBAJA SAEINDIA2020Rulebook.

L. FUTURE SCOPE

Major players in field of all terrain vehicle are Polaris, Yamaha,Hondaandmostofareusedforonlyrecreation purposesinIndia.Theall terrainvehiclescanhavewide applicationinthefieldofagriculture,constructionaland industrial applications where such type of car can be utilized up to its full potential. With minimum modificationforeachtypeofitsapplicationandwithuse oftechnologyandautomationall terrainvehiclescanbe replacedwithtractorsandmanufacturedatcheaperrates thantractors.

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