Design and Fabrication of an ATV Brake System

This assignment document presents a comprehensive report on the design and fabrication of a braking system for an all-terrain vehicle (ATV) as part of a university project. It covers theoretical calculations, component selection, fabrication processes, problem-solving during assembly, and collaborative efforts with other teams. The project aimed to develop a safe and effective braking system for competitive use in BAJA events.

CAREER EPISODE 2
CE 2.1 Project Information
Name of the project: Design and Fabrication of an All-terrain Vehicle
Location of the project: Plot No. 32-34, Knowledge Park III, Greater Noida, Uttar
Pradesh-201306, India
Project Duration: August of 2014 to February of 2015
Organization: Sharda University
Role and Designation during the time: Team Member, Brake Department
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
This project was undertaken by “Team Tornadoes” formed by the students of mechanical
engineering department of Sharda University. This project was about building an ATV or all-
terrain vehicle for participating in BAJA Student, a national level competition and BAJA SAE,
an international level competition.
CE 2.2.2 Objectives developed for the project
The main or primary objectives of the project were:
 To give the best design for developing the ATV
 To design a cost-effective as well as weight-effective ATV
 To fabricate an ATV having the best endurance capability, manoeuvrability and
hill climbing strength

The secondary objective of the project was to create an engineering as well as innovative
environment in the university where the engineering students would get attention for working on
projects, get involved, get inspired and value engineering projects. The project aimed to create an
atmosphere that would support the significance level of projects in and beyond the university.
CE 2.2.3 My Area of work
My area of work was to monitor the activities that were carried out in the braking
system/brake department. I had to carry out an intensive research work and find feasible
calculations for suiting ergonomics as well as the prescribed standards. My main area of work
was to monitor every aspect of the brake department starting from research, theoretical
calculations, brainstorm, prototype fabrication, engineering design to braking system fabrication.
I also had to make sure that all the team members were appropriately following the design plan
and keeping track of the plan.

Team Captain
(Soorya Kalasalivan)
Team Vice Captain
(Arun Tiwari)
Brake
Department
(ME)
Suspension
Department
Engine
Department
Transmission
Department
CE 2.2.4 Project Group
Figure 1: People involved in the project
CE 2.2.5 My responsibilities throughout the project
My main responsibility was to design and fabricate a braking system that would stop the
vehicle by locking all its wheels while the vehicle is running at a speed of 60km per hour. I was
responsible for managing the brake department. I had to conduct brainstorming sessions for
getting unique ideas and selecting an appropriate brake for the vehicle. I had to carry out relevant
research studies for getting an insight into various types of brakes and determining its feasibility.
I had to coordinate with the seniors who handled the brake department in the previous events for
understanding the braking system of motorbikes, cars and tractors. I had to ensure proper
functioning of the system by carrying out regular repair of the assembly components.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
An ATV or all-terrain vehicle can be considered to be a three-wheeler, quad bike, quad,
quadricycle or four-wheeler. ATV can travel by having low-pressure tires. It consists of
handlebars for controlling the steering. It is not considered to be street-legal in most of the states
of the US, Canada and Australia. ATVs are more stable at a slower speed as compared to
ordinary motorcycles. This project was about building a reliable and maintainable ATV that
would be able to serve the recreational user market.
CE 2.3.2 Engineering Knowledge and Skills applied in the project
I have utilized my mechanical engineering skills and knowledge for selecting and
designing the braking system of the ATV. I have applied engineering dynamics and practical
skills to build the ATV. I have utilized my technical knowledge for appropriately using
“SolidWorks” engineering design software. I have used “SolidWorks” for designing the pedal
assembly. I have also used “ANSYS”, analysis software for carrying out the simulation test. I
have been able to use my knowledge of fabrication and machines for assembling and fabricating
the components.
CE 2.3.3 Accomplishment and task performed
The ATH designed me and my team members secured 7th position out of 32 positions in
the BAJA SAE event held at IIT Jamshedpur, India. In another competition BAJA SAE held in
Natrip track, Pithampur India, the ATH designed by us entered among the top 66 vehicles out of
110 vehicles. In the endurance race, our vehicle secured the 56th rank. This project helped me to
inculcate all aspects that are needed for making a successful career in the automotive field.

I selected the disc brake over drum brake for our system because when a disc is exposed
to atmosphere there is better dissipation of heat. Disc brakes require less braking torque for
stopping the vehicle. Disc brakes are durable and can be easily maintained. I had compared
several disc brakes such as Maruti-800 (car), Apache RTR-180 (bike), Pulsar-220 (bike)and
Karizma-220 (bike) by analysing the theoretical calculations of the disc brakes by providing the
braking torque. The actuating force of Maruti-800 was 392.4N, Pulsar-220 was 155N, RTR-180
was 309N and Karizma-220 was 179N. I had accurately used the formula for calculating the
braking torque of the disc brakes (Brake Torque= Area of caliper * effective radius * working
pressure*2 *4* coefficient of friction between brake pad and disc). The brake torque for Maruti-
800 was 769.97N-m, Pulsar-220 was 709.6N-m, RTR-180 was 620N-m and Karizma-220 was
453N-m. Thus, I had selected Maruti-800 disc brake.

Figure 2: Comparison of different Braking System
Maruti-800 disc brake system has high ability to transmit torque, less expensive and
easily available. I was successful in locking the rear wheel so that the vehicle can effectively take
sharp turns. I chose aluminium for better performance of the pedals. I also made use of
“ANSYS” software for performing simulation test. The crucial phase of the project was to carry
out fabrication and assemble all the components. I successfully welded as well as bolted all the
essential components as per the design. The entire project was carried out within the given time.
I was able to enhance my engineering as well as management skills and knowledge while
working on this project.

Figure 3: Brake Circuit and Target Specification
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
One of the main issues faced by me during the assembly of the components was fixing of
the orientation of the master and slave cylinders against the rocker arm of pedals as well as
maintaining the calculation.
2.3.4.2 Solutions

I had interchanged and re-fabricated some parts for fixing the issue. After that, I had used
brake hose, t-joints and hydraulic brake switch for connecting the master cylinder to the caliper
in wheels. I had used dot-3 brake oil and pumped the pedals for creating pressure.
CE 2.3.5 Plan to produce creative and innovative work
I started with the theoretical design of the braking system. The mass of the vehicle along
with its driver was 320kg and the coefficient of friction between the wheel and the street was 0.6.
The deceleration rate was 5.88 m/s2. I had to overcome this deceleration with high braking force.
I had calculated the force to be 1881.6N. With 0.279m wheel radius, I calculated the braking
torque to be 525.71 N-m. This was the minimum braking torque that could be provided to the
vehicle. The innovative approach undertaken by me was to inculcate one hydraulic master
cylinder along with two slave cylinders. The slave cylinder was used for locking the two wheels
in diagonal positions. I had focused on diagonal arrangement for enhancing the safety of the
vehicle. I made a design for installing cutting brakes in the braking system for improving the
braking effect at the time of sharp turns.
CE 2.3.6 Collaborative work
The entire project was effectively carried out with the cooperation and coordination of
the project team members. My team members were respectful and supportive. I was able to
motivate and guide them for achieving success in the project work. I was able to carry out
collaborative activities among the various departments such as suspension, engine and
transmission department.

CE 2.4 Project Review
CE 2.4.1 Project overview
This project was undertaken for building an all-terrain vehicle for competing in the BAJA
Student and BAJA SAE event. The duration of the project was from August of 2014 to February
of 2015. Our project team had to make the best and cost-effective design for developing the
ATV. The secondary motive of this project was to create an innovative atmosphere in and
beyond Sharda University for inspiring the engineering students.
CE 2.4.2 My contribution to work
I made significant contributions to the overall success of the project. I was able to carry
out a significant research work on the various types of brakes that helped me to appropriately
select the disc brake for building the ATV. I was able to produce an effective design of the brake
system and accurately carry out the theoretical calculations. I was able to cooperate and
coordinate with the project team members and other departments for successfully carrying out
this project. I had produced accurate project reports and documents after the completion of the
practical work. I also made attractive PowerPoint presentations for demonstrating the main
features of the project. My dedication, technical competencies and intensive research led to the
success of the project.