Design Analysis and Optimization of an All-Terrain Vehicle (ATV)

Abstract

The paper summarizes the steps taken in finalizing the design of an electric ATV, made for SAE BAJA which provides a platform for undergraduate students to apply the principles of engineering to expose their proficiency in the automotive world. The purpose of the paper is to calculate various boundary conditions on the frame, steering knuckle, suspension arms of a light ATV under extreme conditions and use them to improve the overall design which requires the minimum amount of material while providing a significant Factor of safety. An iterative approach using standard calculations & FEA is discussed in the study for simulation and optimization of the design. For all parts, stress & deformation analysis is performed. For design optimization in the knuckle, topology is done. Von mises Stress, total deformation and safety factor were calculated for each part under appropriate boundary conditions. The study discussed step by step calculations of forces on each component in detail and their simulations with an appropriate degree of precision. Following the methodology shown in the study will be useful in the development of a Light ATV, further, the suggested simulations will ensure the safety of the vehicle. Keywords— Von mises stress, Deformation, Safety factor, Design, Material Selections, FEA, Topology, Knuckle, Frame, Suspension Arms.