DESIGN OF STEERING SYSTEM FOR AN ALL-TERRAIN VEHICLE

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

DESIGN OF STEERING SYSTEM FOR AN ALL-TERRAIN VEHICLE

Barani M1 , Rakul P R2 , Mohammed Thoufeek3, Dr. M.A. Vinayagmoothi4

1 2 3 Student, Dept. of Mechanical Engineering, Kumaraguru College of Technology, Tamil Nadu, India 4Assistant Professor, Dept. of Mechanical Engineering, Kumaraguru college of Technology, Tamil Nadu, India ***

Abstract The Steering system is one of the vital subsystems of a vehicle which provides directional control and stability. In this project we are designing a steering system for an All Terrain Vehicle. An All Terrain Vehicle (ATV) is a vehicle that can travel on all different terrains. As a result, the steering system is designed for the worst case scenario, providing maximum directional control, pure rolling motion to the wheel, and the minimum possible turning radius. The main aim of this paper is to design a efficient steering system for an ATV.

Key Words: ATV,SteeringSystem,Ackermanngeometry,RackandPinion,Design

1.INTRODUCTION

Thesteeringsystemisasetofassembledcomponentsthatguidesthevehicletofollowadesiredcoursebasedonthedriver's input.Thegoalofthesteeringsystemistoprovidedirectionalcontrolforthevehicle,toreducesteeringeffortandofferproper roadresponsetothedriver.

TheAckermansteeringsystemisdesignedusingafour barlinkagemechanisminwhichseverallinkagesmoverelativeto oneanotheranddirectthevehicleinaspecificdirection.Thissystemisusefulinsharpcornerssinceitreducessteeringeffort andfacilitatesmaneuverability.

Incomparisontoothersteeringmechanisms,therackandpinionmechanismisidealduetotheobviousbenefitsofsimple design,easeofmanufacturing,significantlyreducedspacerequirements,andcost effectiveness.

Thepinionofarackandpinionsystemmesheswiththepinion,whichisfastenedtotheendofthesteeringshaft.The pinionisrotatedbyrotatingthesteeringwheel.Themovementofrackisresponsibleforturningofwheelsthroughsteering linkages.

2. LITERATURE REVIEW

Thefollowingliteraturesurveygivesapreviewglimpseofourworkinthisresearchrelatedtodesignofsteeringsystemin anATV.

Mohan poojari et al. [1]: Designeda2 DTurningradiusmechanismbyusingCatiaV5R21consideringtheacquiredbasic parameterracklengthsteeringarmlengthandotherparametersarechangedtoobtaindifferentturningradiusandAckermann percentagevalues.

William F. Milliken and Douglas L. Milliken [2]: InthebookofRaceCarVehicledynamicsItisshownthatifthewheel steersautomaticallywhenitturnsoverabumpordrooporwhenthevehiclerollsinaturnthevehiclewilltravelinapaththat driverdidnotselect.Soitisgoodtokeepzerobumpsteer.

Akshay Pawar and Suraj Zambare [3]: WheelbaseandTrackWidtharedecidedconsideringthesuspensiongeometry, handlingandstabilityofthevehicle.Kingpinoffsetwasdecidedbyconsideringthewheelassemblyandcastorangleselectedso thatitgivesstraightlinestabilityandoptimumself returningactionforbetterhandling.Positionofrackischosenbyconsidering pedalpositionandtoavoidsignificantamountsofbumpsteer.

Shylaen S Keshwani and A. M. Surendra Kumar [4]: TomakecalculationsimpleraC Programwascodedwhichcalculates varioussteeringvaluesneededsuchasAckermannangle,TieRodLength,SteeringRatioetc.Thisprogramwassimulatedunder differentAckermannangle,anditwasinferredthatwhentheAckermannangleincreasestheouterwheelturnslesser,which givesthebettersteeringresponse,andinputvariabilityincreaseshenceitgivessmoothdriving.

Nitish Malik et al [5]: Increasedthediameterofsteeringwheeltoreducethesteeringeffortbecausethedrivereffortto rotatethesteerhasbeenincreaseduponreducingthesteeringgearratio.

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

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Amit Kumar Shakya et al. [6]: TominimizethebumpsteertierodmustbeparalleltoSuspensionA Armssothatduring bumptheInstantaneouscenterofthetierodmeetstheinstantaneouscenteroftheA Armsatinfinity.Inthismanner,thearc travelledbythetierodsandthearmswereequidistanttoeachotherduringsuspensiontravel,andnoforcewasgeneratedalong theracktoproducebumpsteer.

Kshitij N Sable et al. [7]: Thecalculatedvalueswerevalidatedusinglotussharksoftwaretochecktheproperfunctioningof suspensionsystemsandthenthedesigningofcomponentsweredoneinCADSoftwareCATIAV5R21.Allthecomponentsare analysedtotherealworldusingFiniteElementAnalysis

Prashant L Agrawal et al. [8]: Itwasmentionedthatthelengthofthesteeringrackisdirectlyproportionaltotheangleof thesteeringwheelandinverselyproportionaltotheaverage turningradiusofthevehicle.

Sandeep Chaudhary et al. [9]: Whileavehicletakingaturntheouterwheeltravelsmoredistancethantheinnerwheeli.e., innerwheelmakeshigheranglethantheouterwheel.SoHigherthesteeringanglesmallerwillbetheturningradius.

3. MATERIAL AND METHODS

Element C Si Mn P S Cr Mo Ni

Content (%) 0.10 0.20 0.10 0.35 0.50 1.00 0.040 (Max) 0.040 (Max) 0.75 1.25 0.08 0.15 1.00 1.50

Table 1: ChemicalCompositionofEN 353

Mechanical Properties Density (gm/cm³)

Young’s Modulus (Gpa)

Poisson’s Ratio Yield Strength (Mpa)

Compression strength (Mpa)

Ultimate Tensile strength (Mpa)

Value 8.08 190 0.26 440 550 550

Table 2: MechanicalPropertiesofEN 353

SinceEN353hasgoodductilityandfatiguestrengthweuseitforrackandpinion.

4. DESIGN OF STEERING SYSTEM

4.1 Requirements of Steering system

Steeringsystemshouldbedesignedinsuchamannersothat  Itshouldbeaccurateandeasytohandle,  Steeringeffortshouldbeminimum,  Roadshocksshouldnotbetransferredtodriverand

Itshouldprovidepurerollingmotiontowheel

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

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4.2 Design

Methodology

Fig -1:DesignMethodology

4.3 Selection of Steering Geometry

Tractionisanimportantfactorinoff roadracingascomparedtospeed.WechooseAckermannsteeringgeometrysinceitgives highstabilityatlowerspeed.Becauseoftheterrain,thisgeometryissuitableforBAJAvehicleswithaspeedlimitof60kmph.

Fig 2:SchematicDiagramofAckermannSteering[3]

2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal

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

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AccordingtotheAckermannprinciple,theextendedaxesofthesteeringarmshouldmeetatthecentreoftherearaxle. Whenavehicleisturning,theconditionofperfectrollingisreachedwhentheextendedaxisofthefrontwheelsandthe rearaxismeetatapoint.Thispointiscalledinstantaneouscentreofthevehicle.Theinnerwheeldeflectsmorethanthe outerwheelwhileavehicletravelsalongacurvedpathtopreventskiddingwhilecornering

4.4 Steering Design Parameters

PARAMETERS DIMENSIONS

TrackWidth(mm) 1219.2

Wheelbase(mm) 1320.8

LocktoLock 1.25

InnerWheelAngle (Deg.) 48

Distancebetween KingpinCenter Center (mm)

1122.68

GroundClearance(in) 12

Table 3: InitialParametersforsteeringdesigncalculations

4.4 Steering Design Calculations

Ackermann angle

tanα=kingpin kingpincentredistance/2x(Wheelbase)

α=tan 1 (1122.68/2x52x25.4)

α=23.03°θ

Maxinnerwheelangle,Assume,θ=48°

ByAckermanncondition

Cot(Φ) cot(θ)=Trackwidth/wheelbase

(Φ)=28.74°So=29°(Maxouterwheelangle)

Turning radius of the wheel

TurningRadiusoffrontinnerwheel,Ri=wheelbase/Sin(θ) (Trackwidth K.k)/2

TurningRadiusoffrontouterwheel,Ro=Wheelbase/Sin(θ) (Trackwidth k.K)/2

Ri=1729.50mm,Ro=2698.59mm

Turning Radius (Vehicle)

R=(Ri+Ro)/2=2.2m

Ackermann percentage

Ackerman%=Si/Ackermanx100

Ackerman=tan 1 (Wheelbase/(tan(Φ)*Trackwidth))

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

Ackermanpercentage=101%(>100%)oversteer (Assumelocktolocktobe1.25revolution)

Locktolock=SteeringWheelangle/360°

Steeringwheelangle=1.25x360°=450°

Thesteeringwheelmustberotatedabout450°

Steering Ratio

SteeringRatio=steeringwheelangle(Fulllockononeside)/Innerwheelangle =225/48°=5

Steeringratio=5:1

Rack travel

Steeringratio=steeringwheeltravel(fullrotation)/Racktravel

5=(2*π*(5*25.4)*540)/360/Racktravel

∴Racktravel=188.435mm(full)

Ononeside,racktravel=94.2mm

∴Diameterofsteeringwheel

Steeringratio=steeringwheelcircumference/pinioncircumferences(or)

Radiusofsteeringwheel/Radiusofpinion

5=5*25.4/r

r=24mm

d=48mm(pinion)

No of teeth in pinion

Assumemodule=2*m=D/T∴T=D/m=48/2=24

Gearratio=540°/360°=1.25

Gearratio=Numberofteethinrack/Numberofteethinpinion1.25=N/18

Noofteethinrack=30

ImporttheCalculatedvaluesinLotussharksoftwaretocheckthesuspensioncharacter.

4.5 Steering Geometry Setup

Aftergettingthesystemaimsclear,thesteeringiterationsweredoneinLotusSharksoftware.Someofthepredetermined parametersarelistedintheabovetable.

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

Fig 3:LotussharkInterface

Fig 4:WheelTravelinBumandDroop

Final Design Parameters

AfterseveraliterationsinLotussharksoftwarefinalparametersfordesigningthesteeringsystemwerementionedbelow PARAMETERS

DIMENSIONS

STEERINGMECHANISM RACKANDPINION

ACKERMANNANGLE 23.03 STEERINGARMLENGTH 90mm INNERWHEELLOCKANGLE 48Deg OUTERWHEELLOCKANGLE 29Deg STEERINGRATIO 5:1

ACKERMANNPERCENTAGE 101%

TYPEOFSTEERING Oversteering

STEERINGARMLENGTH 91mm

Table 4: Final

DesignParameters

SinceAckermannPercentagegreaterthan100%ThetypeofsteeringwillbeOversteering.Oversteerisatendencyforcarsto turnsharperthanthedriverintended,helpingthetiresgripsharpcorners.

2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

4.6 CAD Modelling

4.7 CAE Analysis

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

RackPinion

MAXIMUMDEFORMATION=0.01133mm

MAXIMUMSTRESS=36.876Mpa

Factorofsafety=8.1

ThedesignisSafe

Fig 8:AssemblingofCADModels

5. CONCLUSION

ThesteeringsystemplaysanimportantroleintheoverallperformanceofAllterrainvehicles.Thisresearchpaperconcluded bypresentingacompletedesignmethodologyaswellasresultingoptimaldesignsthatcanbemanufacturedforthegivenreal timecondition.Itcanbeusedinoff roadingvehicles.Thefollowingconclusionsareobserved:

Thesteeringhasbeendesignedtoproduceminimumturningradiusof2.2mwith101percentage.Asteeringratioof5:1is achievedalongwithlowsteeringeffort

6. REFERENCES

[1] M.Poojari,B.S.Shreyas,R.Muddaiah,A.Raj,andB.S.Babu,“Design,analysisofsteeringsystemandfront suspensionforanElectricAll Terrainvehicle,”in Materials Today: Proceedings,2021,vol.46,pp.2848 2857.doi: 10.1016/j.matpr.2021.03.102.

[2] “WillamF.MillikenandDouglasF.MillikenRaceDynamicsVehicleDynamics”.

[3] Akshaypawar,andSurajZambare,“DesignofSteeringSystemforAllTerrainVehicle,”2018.

[4] S.S.KeshwaniandA.M.SurendraKumar,“REVERSEENGINEERINGOFSTEERINGSYSTEMWITHDEVELOPED EQUATIONFORSTEERANGLE,”2012.

[5] MalikN,AgarwalPandRajputA,“DesignandPerformanceOptimizationoftheSteeringSystemofavehicle,” Trans Stellar, 2017.[Online].Available:www.tjprc.org

[6] V.Saini,S.Kumar,A.KumarShakya,andH.Mishra,“DesignMethodologyofSteeringSystemforAll Terrain Vehicles,” International Research Journal of Engineering and Technology,2017,[Online].Available:www.irjet.net

[7] M.Kshitij et al.,“Design&AnalysisoftheSteeringSystemforAll TerrainVehicle,”2019.[Online].Available: www.ijsrd.com

[8] H.H.KumarB,C.Byrappa,andA.Professor,“ModelingFiniteElementAnalysisAndWeightOptimizationSteering Arm,”2012.[Online].Available:www.ijedr.org

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal

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

Volume: 09 Issue: 07 | July 2022 www.irjet.net p ISSN: 2395 0072

[9] P.L.Agrawal,S.S.Patel,andS.R.Parmar,“DesignandSimulationofManualRackandPinionSteeringSystem,”vol. 2,2016,[Online].Available:www.ijsart.com

[10] S.Chaudhary,G.K.Kantak,P.Sharma,andH.Mathur,“DesignAnalysisandFabricationofM BAJAATV2020,”2020. [Online].Available:www.erpublication.org

BIOGRAPHIES

Barani M

HeispursuingthirdyearBachelor MechanicalinKumaraguruCollege ofTechnology,Coimbatoreandhe is captain of Electrical Baja Team E BLITZfortheyear2022 2023

Rakul P R

HeispursuingthirdyearBachelor MechanicalinKumaraguruCollege ofTechnology,Coimbatore

Mohammed Thoufeek M

HeispursuingthirdyearBachelor MechanicalinKumaraguruCollege ofTechnology,Coimbatore

2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal