Design of Quad Bike (All-Terrain Vehicle)

Project: Quad Bike Design

Location: India
Duration: July 2016 - January 2020

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Our journey to redefine quad bike standards was a testament to resilience, innovation, and the relentless pursuit of excellence. Over a year and a half, we embarked on a project that not only aimed to challenge the status quo in all-terrain vehicle engineering but also to embody the lessons learned from past experiences.

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Technical Specifications of the Vehicle

1. Chassis -- Seamless Tube

2. Wheelbase --1130.5mm

3. Overall   Length of Vehicle -- 1700.276mm

4. Track Width (tire center to center) -- Front:1117.6mm
                                                  Rear: 1016 mm

5. Type of Engine -- 250CC 

6. Tires -- Front:23*7*10
            Rear:22*8*10

7. Mass of The Vehicle -- 210 kgs

8. Ground Clearance -- 330.2mm

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Engineering Excellence in Design

Utilizing Fusion 360 and Solidworks, I have designed and analyzed a vehicle chassis that set new benchmarks. The choice of chrome AISI-4130 for the frame was pivotal, selected for its superior combination of weldability, strength, and manufacturability. This material offered an optimal weight-to-strength ratio, crucial for enhancing quad bike performance.

My work in the team
 

Design of Quad Bike:

The following design methodology was used during the design:

• Requirements

• Design Calculations and Analysis

• Considerations

• Acceptance

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Material Selection:

The material chrome AISI-4130 (Annealed at 870° C) is used in the frame design because of its good weldability, relatively softness, and strength as well as good manufacturability.

AISI 4130 has been chosen for the chassis because it has structural properties that provide a low weight-to-strength ratio. The presence of chromium makes it a corrosion-resistant material. A 1-inch diameter tube with a thicker wall is used. It is assured by analysis in ANSYS simulation software. The various Physical properties of the material are as follows.

Physical Properties of Material:

1. Density  --- 7.85 kg/m3

2. Hardness, Brinell ---- 207

3. Tensile Strength, Ultimate ---- 670 Mpa

4. Tensile Strength, Yield --- 430 Mpa

5. Modulus of Elasticity -----207 Gpa

6. Bulk Modulus -----140 Gpa

7. Poisson Ratio ---- 0.3

8. Machineability ----- 65%

9. Shear Modulus ---- 80.0 Gpa

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Precision in Impact Analysis

My dedication to vehicle safety and durability was evident in my comprehensive Impact Analysis using Ansys Workbench. I achieved remarkable precision in my front and back impact analyses, complemented by theoretical calculations. This meticulous approach resulted in error margins of only 0.05 and 0.07 for side impact analysis, showcasing my analytical prowess and commitment to predicting and improving the vehicle's structural integrity under various conditions.

Please go through the document I have prepared for the analysis and calculations: Design and Analysis Report

Please go through the document I have prepared for the analysis and calculations for Suspension Systems: Report
 

Learning from Losses

Our path to success was shaped by adversity. Participating in two national-level events and facing losses by narrow margins was a turning point for our team. These experiences, though challenging, were invaluable. We embraced these setbacks as opportunities for growth, meticulously analyzing our shortcomings and integrating these lessons into our design process. This resilience and determination to learn from failure culminated in the development of a product that not only faced adversity head-on but also triumphed, securing a place on the podium. This journey underscored the critical skills we honed through adversity, proving that failure is not a setback but a stepping stone to success.

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Project Impact and Recognition

This project was a bold statement in automotive engineering, integrating advanced materials with innovative design and precise analysis to redefine quad bike performance and safety. The recognition at the Quad Bike Design Challenge 2020 was a testament to our hard work, innovative spirit, and the invaluable lessons learned from previous setbacks.

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Looking Forward

The success of this project has laid a strong foundation for future innovations. Committed to exploring new technologies and materials, our team is dedicated to continuously improving the design, safety, and performance of all-terrain vehicles. This project not only showcased our capabilities but also highlighted our growth mindset, driven by the belief that every challenge is an opportunity to learn and excel.

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