Carleton University

Department of Mechanical and Aerospace Engineering

MECH 4003 A Mechanical Systems Design – Fall 2018

DESIGN OF THE SHAFT DRIVE FOR AN OFF-ROAD MOTOCYLCE

Description
Off-road motorcycles typically have chain-and-sprocket drives from the transmission output
shaft to the rear wheel. Sometimes enclosed transmission shafts and gear drives instead of a chain and
sprockets are used. The advantage of chain drives is light weight, but exposure to the dust and mud of
off-road riding reduces their reliability. Enclosed shaft drives are protected from outside environment.
The objective of the design project is to design a lightweight shaft-drive system for an off-road
motorcycle, which is a retrofit from an on-road motorcycle. Assume an engine of 60 hp at 9000 rpm will
be used. Low gear in the transmission has a ratio of 1:4, and the final drive ratio from transmission
output shaft to rear wheel should be approximately 1:3.5. At least one universal joint will be needed in
the driveshaft to accommodate the suspension motion. Note the off-road motorcycle is retrofit from an
on-road motorcycle, therefore, typical dimensions for an on-road motorcycle should be used.
Figure 1 shows a concept design, with combination of two bevel gears. It will be your task to
perform the preliminary and detail deigns of this shaft drive system, including every individual part in
the system. Your final design should have considered all possible modes of failures (static, fatigue, etc).
This design project will be carried out by design teams of approximately five students such that each
member can take responsibility for some specific part of the design as well as contribute towards the
overall design process. Since only one design report is required from each team, it is important that
each student make their contribution to the project visible through well documented, signed, and dated
work.

Shaft Drive

Figure 1 Concept Design for Shaft Drive

Project Outline 2018-08-29

Deliverables and Evaluation

The various deliverables, values, due dates, and some evaluation details are provided below.
The first three deliverables will be graded “on-site” by the teaching assistants during the lab sessions.
Specific details regarding the design report and layout drawing, including detailed a marking scheme will
also be provided later in the term.

Research – 1% (due lab session week of September 24th)

• perform research (library, internet, journals, Patent Office, etc.) on the general problem and
similar systems
• summarize/present research verbally to teaching assistants

Design Requirements/Constraints & WBS/Gantt Chart – 2% (due lab session week of October 8th)
• develop a list of design requirements and constraints (1 page, point form summary)
• develop a WBS and a Gantt Chart

Preliminary Design Layout – 2% (due lab session week of November 5th)

• select the best concept and develop a preliminary design layout
• hardcopy of CAD layout drawing (2D or 3D)

Design Report – 20% (due by 17:00, December 4th in MECH3269 Lab Session)
• based on a design layout drawing
• journal-style report, 5 pages maximum, not including layout drawing; previous, graded
deliverables to be included as an appendix
• Deign calculations for individual components need to be included
• 0.75” margins, 10 pt. font (minimum)
• Detail requirements to follow

Project Outline 2018-08-29