Design, Analysis & Fabrication of the Power-train System for All-terrain Vehicle

SAE BAJA is a national level All-Terrain Vehicle building and racing competition, the main objective of this paper is to design analyse and fabricate a reliable and efficient powertrain unit for an All-Terrain Vehicle. Powertrain system comprises an Engine, Transmission unit, Drive axle, Tyres. Purpose of design is that the vehicle must carry approximately one ton of load for 100ft, the vehicle must not get stuck in the mud pool and pass easily, the must be able to climb the grad ability with minimum drive slip and while performing the system must be reliable and system must not fail under any circumstance. During the designing phase of the system, the focus was on to minimize the weight and while doing this optimize the expense without any hamper to the performance and reliability of the system. This paper’s purpose is to study the system and the designing of the two stage gear reducing unit, coupling and aligning methods for CVT (continuously variable transmission) with engine and the double reduction gear train system. Briggs and Stratton engine with 10hp @ 3200 RPM and 18.9 N-m @ 2600 RPM was selecting as power producing device, CVTech CVT with 0.4:1 as higher ratio and 3:1 as lower ratio was selected for transmitting power at variable conditions, a double stage reduction gear train system was used for the to compensate the torque requirement, TATA NANO drive axle were selected for the power transmission purpose from gear train to the wheels. The designing was done one CATIA V5 R21 and assembly were done on PTC Creo 3.0. The design has been evaluated by using FEA software like ANSYS 19.1. Further in the manufacturing phase the gear train casing was machined on vmc, shaft were made on centre lathe machine, and gears were made using hobing process. Hence, all the components were assembled and proper testing was carried out to get the practical evidence of the performance and reliability of the system for the rough terrain as there are in the actual competition.