3rd National Conference on "Changing Technology and Rural Development", Dec 2018,

Organized By Rajendra Mane College of Engineering & Technology, Ambav, India

Design and Fabrication of Single Speed Double

Reduction Gearbox of Baja vehicle
1
Kaushal Sankhe, 2Swapnil Kuwar, 3Prof. A. R. Suware
1, 2,3
Dept of Mechanical Engineering, RMCET / Mumbai University, India

Abstract : This report is about design, fabrication of Baja SAE ATV(All Terrain Vehicle) drive train.Baja SAE is an
intercollegiate engineering design competition for undergraduate and graduate engineering students. As we know the
participation of students in SAE Baja competition is increasing year by year.The object of the competition is to simulate
real-world engineering design projects and their related challenges. Each team is competing to have its design accepted
for manufacture by a fictitious firm. The students must function as a team to design, engineer, build, test, promote and
compete with a vehicle within the limits of the rules. Calculations are done with respect to required maximum torque
and maximum speed. Our transmission system is assembly of CVT (continuous variable transmission) and single speed
gear box.

Keywords — ATV, All Terrain Vehicle, Briggs and Stratton Engine, CVT, Gear Box, SAE BAJA INDIA, Transmission.

I. INTRODUCTION First is gross weight which include overall vehicle weight

including driver weight then tyre friction coefficient and
This report will give brief idea of SAE BAJA ATV radius etc that we have mention below.
Transmission System and their actual engineering design
 Gross weight of the vehicle
and formulation. The content describes the formal equation
 Tyre radius
and describes generation of concepts and explanations of
 Frontal area
the final systems. The report and calculation that we have
 Air density
done is fully based on finding a gear reduction ratio with
 Aerodynamic drag
respect to the design and manufacturing.
 Maximum speed
Our transmission system is combination of CVT  Coefficient of rolling resistance
(Continuous Variable Transmission System) and Gear Box.  Gradeability
We have to consider different parameters of CVT for
 CVT max and min reduction
calculation. As per the All Terrain Vehicle we have to look
 Engine performance parameters
out for maximum torque and speed basis on this the
calculations have to be done. In SAE BAHA competition This parameters helps us to find the total required gear
there is event of hill climb, we have to ensure that the reduction.
BAHA vehicle climbs the hill as per these we have to
2.1 design and working
lookout for the maximum torque at which vehicle must
climb the hill.
We have to also look for the vehicle maximum acceleration
as per the acceleration event in SAE BAJA. We have to
consider both for maximum torque and the maximum
Acceleration. The engine Briggs and Stratton which we
have to use which is specifically assigned by the event
organizer of SAE BAJA. Initially the engine have low
torque, to increase torque we need to place CVT followed
by Gear Box. It is the best combination to increase the
performance of the car.

II. DESIGN AND CONSIDERATIONS Fig.1: Gear box 2D view

2.2 Considerations The Fig.1 shows the actual design and arrangement of gears
and Gear Box. The arrangement shows the meshing of the
For design we have to look for different parameters to gears. The power transmission of power is from one end to
achieve the maximum torque and acceleration. This the last end. As par shown in CAD model from left to right
consideration helps to find the total required gear reduction.

81 | CTRD2018022 © 2019, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Special Issue - CTRD - 2018

the first gear is input gear on which CVT output is mounted

and input is connected to engine. Then the power is Fig.2: Hill climb
transmitted from first gear to second gear which is
compound gear that is on single shaft two gear are Grad Resistance GR :-
mounted. From second gear to third gear power is (W x Ѳ ) = 2403.45 x 30.96
transmitted from the shaft. Third gear and forth are mesh = 1236.428415 N
each other and power is transmitted from third gear to forth
gear. Gear reduction done by considering calculated ratio. Total Road Load=RRL+AR+GR
= 1780.3548 N
The ratio are calculated by considering different parameters
with respect to required maximum torque and acceleration.
Torque Required at 60% Gradeability :-
It is fully depend on CVT reduction. . CVT have a number
= Total road load x Tyre radius
of gear ratio which have to increase power. It helps to
= 1780.3548 x 0.2921
adjust vehicle’s engine torque in different number of ways.
= 520.0416 Nm
CVT output shaft is then connected to single speed gearbox.
This gearbox helps to give required output torque and
CVT Ratio :-
speed. By properly turning of CVT we improve power of
vehicle.
2.2 Calculation For different engine RPM we can find different CVT
Gross weight of the 2403.45 N reduction or ratio. It is as shown below
vehicle(W)
Tyre radius(R) 0.2921 m Considering engine rpm as 2000
Frontal area(A) 0.923 m2 Then CVT reduction will be
Air density 1.122 kg/m3
Aerodynamic drag 0.44
coefficient(Cd)
Maximum speed 16.66 m/sec
Coefficient of rolling(µ) 0.2
Resistance (loose sand) =2.686
Coefficient of rolling 0.8
Resistance (Solid sand) Engine speed vs toque chart
Gradeability 60% 30.960
tan Ѳ 0.514439

Rolling Resistance (Loose Sand) RRL:-

(W x µ) = 2403.45 x 0.2
= 480.69 N
Rolling Resistance (Solid Sand)RRS :-
(W x µ) = 2403.45 x 0.8
= 1922.76 N
Air Resistance AR:-
= ½ x ₰ v2 Cd Graph.1: Briggs & Stratton M19H 10.0 HP Net Torque
= ½ x 0.923 x 1.122 x 16.66 x 0.44 Ref. briggsracing.com/default/files
= 63.2364 N
Gradeability 60% :- Total torque at CVT output = engine torque*CVT reduction
tan Ѳ = 60/ 100 =18.62*2.686
= 30.96 = 50.01332 Nm

We need torque to the wheel that is 520.04Nm

So we have to take gear reduction by considering extra
allowance that is 11
Maximum torque at wheel=
(total torque at CVT output *gearbox reduction)
=50.01332*11
=550.146 Nm
Maximum torque at wheel= 550.146 Nm

This gear ratio fulfill our requirements

82 | CTRD2018022 © 2019, IJREAM All Rights Reserved.

 3rd National Conference on "Changing Technology and Rural Development", Dec 2018,
Organized By Rajendra Mane College of Engineering & Technology, Ambav, India

The maximum gear reduction is 11 so we need to divide it III. CONCLUSION

in two stage for better performance first stage is 3 and
second stage is 3.8 We choose above custom gear drive transmission system.

Now for first stage reduction ratio 3 the teeth on gear 1 To do our analysis, we generally have analyzed the overall
should be 16 and gear 2 should be 48 system to find what desired torque and speed. CVT
transmissions were analyzed to find the resulted torque and
And for second stage reduction ratio 3.8 the teeth on gear 3 speed to the wheels. for max torque we decided to use the
should be 16 and gear should be 60. single speed double reduction gear box. By considering
That is different parameters like weight and compact size custom
gear box is perfect option for BAJA Vehicle. CVT with
n1=16 n2=48 n3=16 n4=60 single speed gearbox is combination for max power
As we going to design BAJA Vehicle we have to reduce transmission.
weight and make it very compact. As the compact design of
REFERENCES
BAJA Vehicle the gearbox should be very compact.We
need to work more on it. [1] CVTech

2.3 MATERIAL CVTech-AAB Available:

http://www.numeriquetechnologies.com/cvtech/Catalo
2.3.1 Gear Material
gueCVTechAAB_US_%202013.pdf
The material that we are using is EN8 Medium Carbon
[2] Design of a Drivetrain for Sae Baja Racing Off Road
Steel which is readily machinable in any condition. It is a
Vehicle [Vol-1, Issue-4, July- 2015] ISSN: 2454-1311
medium strength steel and has good tensile strength.
[3] Briggs & Stratton M19H 10.0 HP Net Torque Ref.
EN8 is suitable for the manufacturing of parts such as gear,
briggsracing.com/default/files
shaft, keys etc. it can be further surface hardened by
induction processes, producing components with enhance
were resistance.
Max Stress is around 700-850 N/mm2
Yield Stress is 465 N/mm2
Chemical composition:-
Carbon 0.36-0.44 %
Silicon 0.10-0.40 %
Manganese 0.60-1.00 %
Sulphur 0.050 Max
Phosphorus 0.050 Max

2.3.2. Casing Material

Casing material that we are using is 6061 aluminum. This
will help in weight reduction. This alloy is part of the 6000
series of alloy. As such, its major alloying elements are
magnesium and silicon .magnesium is added to increase
strength, while the silicon is added to reduce the metal
melting temperature.
Tensile Strength 241 N/mm2
Yield Strength 145 N/mm2
Chemical composition:-
Magnesium 1.2 %
Silicon 0.8 %
Copper 0.4 %
Chromium 0.35 %

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