Design and Fabrication of Gear Reduction Box of an ATV

ANUP V

4NI13ME015

BHAT KRISHNA

4NI13ME022

CHETANKUMAR V
SALIMATH

4NI13ME027

The NATRAC testing facility,

Pithampur

26 degree Hill climb

Maneuverability
run

The Event Venue

Introduction
*Engine specs: Briggs & Stratton 10hp OHV
Max torque: 20.3 Nm @ 2600rpm
Max power: 10hp @ 3800rpm
Idling rpm permitted: 1750 rpm
*Projected vehicle weight: 220kg
weight distribution:40:60
*Problem statement: Come up lightest weight
transmission system to propel the buggy through harsh
terrains. The vehicle must be able to climb an incline of 26
degree. High speed not to exceed 60kmph.

Literature review
Sl Author &
No year
1 Rishabh
Jain, Dr. P S
Ranjit.
July- 2015

Title

Analytical
Study on the
Performance
Analysis of
Power Train
System of an
Electric
Vehicle

Chul-Ho
Kim KeeMan Lee
2009

Design of a
Drivetrain for
Sae Baja
Racing
OffRoad
Vehicle

Name of the Comments

journal
International
The main objective of this paper
is to provide the in detail
Journal of
knowledge about the Drivetrain
Advanced
of BAJA vehicle.
Engineering,
Management
and Science
(IJAEMS)
World Electric
An analytical simulation
algorithm is developed to
Vehicle Journal
estimate driving performance of
Vol. 3
a designed power train system of
a model vehicle.

Sl No

Author & year Title

Hudayam
Basak& Ahmet
Taskesen
June 2006

Mehmet Bozka
Peter Fietkau
2009

Name of the
journal
Comprehensive Wiley Periodicals
Gearbox Design
Inc.
Using Expert

System
Techniques

Empirical model
based
optimization to
reduce noise

Elsevier Science
Limited

Comments
A complete
analysis and
design of widely
used gearboxes
in industry is
carried out using
efficient CAD
software.

Provides
empirical model
based
optimization of
noise caused due
to the increased
number of gear
teeth and axial
clearance.

Sl No Author & year

5

V. Ramamurti
P. Gautam& A.
Kothari
27 April 1995

Title
Computer-aided
design of a two
speed gear box

Hui-Bo He, Hua- Optimal Design of

Ying Li,Sung-Ki
a Tilling Machine
Lyu,
Reduction Gearbox
Sung-Hoon

Tak,
Sung-Min Moon
and Qi Zhang

Name of the
journal
Elsevier Science
Limited

International
Journal Of
Precision
Engineering And
Manufacturing

Comments
A Computer-Aided
design methodology
for two-speed
gearboxes is
presented in this
paper.

The reduction
gearbox of a tillage
machine was
optimized using a
Mat lab program,
hence improving the
design efficiency.

Sl No

Author & year

Title

Dr. Gary B &

Pamela S
Williams

Design of an
SAE Baja
Racing OffRoad Vehicle
Powertrain

Christopher
Boyle &
Raymond Casola
2012

WPI SAE Baja

Vehicle

Name of
the journal

Honors
research
projects

Comments

Provides a
methodology of fixing
the leading
dimensions of a twostage spur gearbox
with all the necessary
dimensions and
calculations.
saejournals.o Improvisation over the
rg
previous years Baja
vehicle by lowering

the overall center of

gravity.

Sl No

Author & year

Title

Name of the Comments

journal

James Tauby &

Jesse Taylor

Calculations for
design for
powertrain

saejournals.or Provides calculation

g
modules to solve
drive train problems.

10

Erin Ebsch, Jenna

Kudla, Calvin
OBrien, and
Bridget Quick
2012

Designing and
building a gear
reduction system

saejournals.or
Design of a gear
g
reduction system,
with minimal increase

in weight of the
vehicle.

Methodology

1.Total Tractive Effort (TTE) = RR+AR+GR

2. RR = GVW x fr
3. AR = * * V2 * A *Cd
4. GR = GVW x sin()
5. Maximum Tractive force i.e. TE Max= * WR
6. Tw = Te* iglow * transmission

REDUCTION CALCULATIONS
Wei
Partic ght
ulars
N
(220
+70)
formul *9.8
a
1

GR5 GR
5
60
Wsi
Wsin n(3
(28. 0.96
81)
)

GR
70

AR

TR
RR 55

0.5*rh
Wsin( o*A*c fr*
34.99) d*v^2 W

TR6
0

TEm TEma
TR70 ax55 x60

TEma
x70

mu*Wr
ear

14
71.
39. 47
82 40 1564 1731. 1495. 1463.7 1398.4
86
6 .027
859
659 46551
14

1370 146
60.66
2844 .976 3.52 1631. 93469
Value .9
118 903 36085 8
0.5*1.
12*1.
055*0
Tanin Tani
.44*1
Comm
v(0.5 nv( Taninv 5.277 frconcrt
ents
5)
0.6) (0.7)
^2
0.014
28.8
1
0.50
2829
357

30.9
6 34.99
0.54
035 0.610
394 69071

55km
ph
15.27
77777
8

rad

rad

m/s

rad

mucon Wd=.4
crt=1
/.6

Torque n
wheels
Nm
TR*Dyna
mic
rolling
radius

448.5052
95

Total
reductio
n

Gearbox
reductio
n

Tw/
TR/CVT
(cvteff*Te underdriv
)
e rtio

32.04753
805

CVTeff=0.
75
33
(standardi
se)

11

Plan of Action

*With the designs solidified, we would execute the fabrication

plan which includes heat treating, external machining done by
outside sponsors in addition to machining done by members.
With possession of all gearbox components, assembly would
occur
* Under the three-month time constraints to finish the project
we will design and analyse model by end of November 2016
and get the fabricated reduction box ready by end of
December 2016.

Cvtech AAB CVT purchased by

the team

Proposed powertrain assembly

GANTT CHART

THANK YOU