All-Terrain Vehicle

CHAPTER 1
INTRODUCTION
ATVs are vehicles used mainly for military purposes and are now widely used for off-road
transport and in search and rescue operations. Current researchers have improved certain safety
aspects of the ATVs, for example is the rollover prevention which is proven and applied on bicycle
model. A device to control rollover is also designed based on predictive functional control. This
approach is demonstrated successfully on the simulation test bed. The rollover indicator of ATV
is also can be estimated from the tire stiffness observer. Other researchers also improved the
control of ATV by using autonomous control. While the control schemes are successfully
minimize the ATV accidents, the feeling and pleasure of riding an ATV are reduced by the
autonomous system itself. ATVs are also studied in term of dynamic performance for some
interested researchers. Such studies are the simulation of the ATV steering system and estimation
of ATV dynamic parameters. Designing and modeling of ATV are important for the development
of ATV itself. Available software such as CATIA is used in the digital development of ATVs and
their components. The advantage of using computer aided design (CAD) software to design the
ATV is proven by the simple fitting and assembly virtually.

The objective of the work is to develop All-Terrain Vehicle (ATV) roll cage, analyze for
feasibility, safety, economy and physical testing. The aim of this work is to modify the usual singe
seater all-terrain vehicle into a 3 seater electric vehicle, conforming all standards so that the vehicle
can be utilized for the event as well as, it can be utilized in college or campus level for transit as
well as a good carrier afterwards. One more important phenomenon is the durability of the vehicle.
In order to sustain durability of the vehicle, the roll cage of the vehicle is validated using CAE and
FEA techniques for various loading cases statically and dynamically. Different cases like static &
dynamic front impact, static & dynamic rear impact, side impact, front & side roll over, and
torsional rigidity are considered. Based on CAE analysis, a prototype model is manufactured and
physically tested and validated as per Design Validation Plan (DVP). Also the vehicle is tested for
durability by subjecting it to endurance run for 2 hours on a torcher track. As it is electric vehicle,
subjected to all electric vehicle standards such as AIS 038 & AIS 048. In order to test the vehicle
for AIS 038 compliance, a separate water turf is designed and similar electric all-terrain vehicles
are tested for water effects. After the endurance run and water testing, vehicle roll cage was

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 1

 All-Terrain Vehicle

inspected for any visible deteriorations or defects such as cracks, welding defects, etc. No defects
were noticed.

World energy consumption has been increasing for various reasons which include population
rise, enhancement of quality of life, industrialization, increased transportation of goods & people,
etc. There are several types of fuels available, mainly fossil fuels, but the major problem with the
fossil fuels is that they are limited in source. All fossil fuels are non-renewable and eventually be
depleted. And also, energy generation from them causes environmental pollution. In order to
sustain in future, alternate fuels & energy sources are obvious choice. One of the major alternative
energy is electric energy as being a clean energy and also available in abundance. There is good
and solid development and research happening in automobile industries for electric and hybrid
vehicles. In order to push the development and improve awareness in electric technologies, a roll
cage of an all-terrain vehicle with electric drive system is developed. There are various events
which are conducted for the all-terrain vehicles with regular engines running on gasoline. The
major problem with these ATV is that they have no utility value after the event gets over and they
usually just lie idle in college campuses. To tackle this problem as well as to add a utility factor to
these all-terrain vehicles, this roll cage supports driver along with 2 passengers as well as luggage
capacity, so that the vehicle can also be used in college campus for travel or goods carrier. Also
the vehicle being electric, the operation of vehicle will be easy and clean with respect to other
vehicles.
The objective of the work is to develop All-Terrain Vehicle (ATV) roll cage, analyze for
feasibility, safety, economy and physical testing. The aim of this work is to modify the usual single
seater all-terrain vehicle into a 3 seater electric vehicle, conforming all standards so that the vehicle
can be utilized for the event as well as, it can be utilized in college or campus level for transit as
well as a good carrier afterwards. One more important phenomenon is the durability of the vehicle.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 2

 All-Terrain Vehicle

CHAPTER 2

METHODOLOGY

2.1 EXISTING METHODOLOGY

The operation of all-terrain vehicles (ATVs) by youth has contributed to the incidence of serious
and fatal injuries among children. This study explored factors related to the frequency with which
youth wore a helmet and refrained from engaging in three risky driving behaviors (driving at risky
speeds, on paved roads and on unfamiliar terrain) while operating an ATV. Youth (n = 248) aged
9–14 from central Ohio and one of their parents completed self-report measures of ATV safety
behaviors, youth general propensity for risk taking, protection motivation and parental behaviors
to facilitate youth safety. Data from two focus groups provided insight on quantitative results.
Analyses revealed considerable variation in the frequency with which youth performed the safety
behaviors, with 13- and 14-year-olds reporting less frequent safe behavior than 9- to 12-year-olds.
Multiple regression analyses suggested that parental behaviors, such as providing reminders to
wear a helmet, were associated with more frequent helmet use but were not associated with risky
driving behaviors. Youth’s general propensity toward risk taking was not associated with helmet
use and only associated with risky driving behaviors among the 13- and 14-year-olds. Self-efficacy
was an important predictor across both age groups and behaviors. Implications for injury
prevention are discussed.

All-terrain vehicle operation and injury risk

The operation of all-terrain vehicles (ATVs) by youth causes serious and sometimes fatal
injuries. ATVs have three or four wheels with low-pressure over-sized tires, are designed for off-
road use and can travel at speeds of over 60 miles/h. Youth often lack the physical strength, motor
skills and cognitive maturity to operate ATVs safely, increasing their injury risk. Both the
American Academy of Pediatrics and the US Consumer Product Safety Commission have issued
official statements that youth under the age of 16 should never operate ATVs. Despite such
warnings, youth 16 years of age operate ATVs frequently. ATVs are especially common in
agricultural and rural areas. In 2001, almost 40% of farms in the United States reported owning at
least one ATV. In a nationally representative sample, about half of youth aged 10–19 living on
farms in the US reported having operated an ATV. Children and adolescents account for a
DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 3
 All-Terrain Vehicle

disproportionate number of ATV-related injuries and deaths. Between 2001 and 2010, more than
361 000 children under the age of 16 sustained ATV-related injuries that required treatment in an
emergency department. ATV operators under the age of 16 are 3.9 times more likely than operators
older than 16 years to sustain injuries requiring treatment in an emergency department. Children
younger than 16 accounted for almost one-third of all deaths from ATVs between 1982 and 2008,
with 11% of deaths experienced by children under 12 years of age.

2.2 PROPOSED METHODOLOGY

ATV operation and injury risk

The operation of all-terrain vehicles (ATVs) by youth causes serious and sometimes fatal
injuries. ATVs have three or four wheels with low-pressure over-sized tires, are designed for off-
road use and can travel at speeds of over 60 miles/h. Youth often lack the physical strength, motor
skills and cognitive maturity to operate ATVs safely, increasing their injury risk. Both the
American Academy of Pediatrics and the US Consumer Product Safety Commission have issued
official statements that youth under the age of 16 should never operate ATVs.

Despite such warnings, youth 16 years of age operate ATVs frequently. ATVs are especially
common in agricultural and rural areas. In 2001, almost 40% of farms in the United States reported
owning at least one ATV. In a nationally representative sample, about half of youth aged 10–19
living on farms in the US reported having operated an ATV.

Children and adolescents account for a disproportionate number of ATV-related injuries and
deaths. Between 2001 and 2010, more than 361 000 children under the age of 16 sustained ATV-
related injuries that required treatment in an emergency department. ATV operators under the age
of 16 are 3.9 times more likely than operators older than 16 years to sustain injuries requiring
treatment in an emergency department. Children younger than 16 accounted for almost one-third
of all deaths from ATVs between 1982 and 2008, with 11% of deaths experienced by children
under 12 years of age.

Reducing risk through safer behaviors

Given the current widespread use of ATVs by youth in rural and agricultural areas, a harm
reduction approach to reducing ATV-related injuries may be beneficial. Such an approach focuses

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 4

 All-Terrain Vehicle

on increasing safety practices and reducing risky behaviors. A mix of empirical evidence, expert
opinion and anecdotal observations has identified several target safety behaviors that can reduce
the likelihood or severity of ATV-related injuries. We focus specifically on two types of youth
behaviors: wearing a helmet and refraining from engaging in risky driving behaviors (driving at
high speeds, driving on paved roads, carrying a passenger and driving on unfamiliar terrain).

Wearing a helmet

For several decades, injury experts have recommended that all youth wear helmets while
operating an ATV. Examining data from the National Electronic Injury Surveillance System and
fatality figures compiled by the Consumer Product Safety Commission, Rodgers estimated that
wearing a helmet can reduce the risk of death from an ATV accident by 40% and could reduce the
likelihood that a given injury involves the head by 64%. More recent studies support those findings
and suggest that helmets may reduce Injury Severity Scores.

Refraining from risky driving behaviors

Common risky driving behaviors include driving too fast, driving on paved roads, carrying a
passenger and driving on unfamiliar terrain. Refraining from these behaviors can reduce injury
risk. Researchers and safety organizations advise young riders to limit their speed when operating
ATVs, and the American Academy of Pediatrics recommends installing speed governors (devices
that limit maximum speed) on ATVs used by youth. Support for this recommendation comes from
epidemiological and clinical studies that have found that excessive speed is a major risk factor in
ATV-related fatalities. Operators are also urged to avoid driving ATVs on any public roads, as
doing so increases the risk of collision with other vehicles. Most states have legislation prohibiting
ATVs from public roads. Driving on paved public roads may be particularly dangerous, as ATVs
are designed for off-road use only.

Several studies have found higher fatality rates in crashes that occur on paved roads
compared with off-road crashes. Many ATVs are designed to be operated by a single rider only,
and prohibiting youth from carrying passengers while they operate an ATV is also likely to reduce
injury risk. Finally, ATV operators are urged to refrain from driving on unfamiliar terrain, where
they may be less able to avoid steep or irregular terrain that can cause the ATV to roll over and
seriously injure or kill the operator.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 5

 All-Terrain Vehicle

Influences on safety behaviors

Researchers have identified both parent-level and child-level variables associated with youth
safety behaviors. These influences have been studied in a variety of contexts but have not been
studied specifically in relation to ATV safety behaviors.

General propensity for risk taking

Longitudinal studies have found that a youth’s general propensity to engage in risky behaviors
(e.g. how often a child does something dangerous on a dare or breaks a rule set by parents) is
associated with specific risk behaviors, including initiation of sexual activity and substance use
and with risk for injury. A general propensity for risk taking may be negatively associated with
the performance of ATV safety behaviors.

Youth protection motivation

Ronald Rogers developed protection motivation theory (PMT) to explicate the relationships
between one’s beliefs about potential harm and the likelihood of taking protective action. PMT
states that an individual’s intention to perform a specific threat-reducing action (e.g. wearing a
helmet while operating an ATV) is a function of two parallel processes: ‘threat appraisal’ and
‘coping appraisal’. In threat appraisal, individuals evaluate the extent to which they: (i) feel
personally vulnerable to the health threat (‘susceptibility’) and (ii) perceive the potential threat as
leading to severe negative consequences (‘severity’). In coping appraisal, individuals assess: (i)
the likelihood that the suggested threat-reducing action will actually reduce the risk of the health
threat (‘response efficacy’) and (ii) the degree to which the individual feels capable of performing
the suggested action (‘self-efficacy’).

PMT constructs have been useful in a variety of health contexts. With regard to youth populations,
perceived severity has been found to predict teens’ intentions to limit alcohol consumption, and
threat appraisal has been found to predict seatbelt use among newly licensed teenage drivers.
Regarding populations exposed to agricultural hazards, PMT has been used to design interventions
to increase adherence with the North American Guidelines for Children’s Agricultural Tasks.
Although these youth-level variables have been studied in relation to a variety of health behaviors,
they have not been studied with regard to ATV safety behaviors.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 6

 All-Terrain Vehicle

CHAPTER 3
TESTING AND ANALYSIS OF ATV

3.1 Front Impact Analysis

The front impact analysis is carried out to test the vehicle roll cage integrity and strength to
withstand forces under frontal impact. For this around 3.5G force is evenly distributed on the front
portion nodes and the nodes on rear side of the roll cage are fixed in displacement as shown in
figure a. Based on it, the simulation is performed and result of same is shown in figure 3.1 b & c.

Fig 3.1: (a) Boundary Conditions (b) Von-Mises Stress (c) Total Deformation

3.2 Rear Impact Analysis

Rear impact analysis is carried out to test the vehicle roll cage integrity and strength to withstand
forces in a rear impact. For this, around 3.5G force is evenly distributed on the rear portion nodes
and the nodes on front side of the roll cage are fixed in displacement as shown in figure a. Based
on it, the simulation is performed and result of same is shown in figure 3.2.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 7

 All-Terrain Vehicle

Fig 3.2: (a) Boundary Conditions (b). Von-Mises Stress (c). Total Deformation

3.3 Side Impact Analysis

Side impact analysis is carried out to test the vehicle roll cage integrity and strength to withstand
forces in a side crash simulation where vehicle is simulated as it is hit from one of the sides. For
this, around 3.5G Force is evenly distributed on one of the side portion nodes and the nodes on the
other side of the roll cage are fixed in displacement as shown in figure (a). Based on it, the
simulation is performed and result of same is shown in figure 3.3 (b) & (c).

Fig 3.3: (a) Boundary Conditions (b). Von-Mises Stress (c). Total Deformation

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 8

 All-Terrain Vehicle

3.4 Torsional Rigidity Analysis

Torsional Rigidity analysis is carried out to test the vehicle roll cage integrity and strength to
withstand torsional forces in a side roll over scenario. Roll cage is subjected to torsional loads
while cornering when one wheel goes over a bump. Its equilibrium diagram is shown as in figure
3.4.

Fig. 3.4: Equilibrium Diagram for Torsional Rigidity Analysis

For this, around 0.3G force is applied on front left suspension point nodes in upward direction and
in front right suspension point nodes in downward direction. Rear end of the roll cage is
constrained as shown in figure 3.4.1 (a). Based on it, the simulation is performed and result of
same is shown in figure 3.4.1 (b) & (c).

Fig 3.5: (a) Boundary Conditions (b) Von-Mises Stress (c) Total Deformation

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 9

 All-Terrain Vehicle

3.5 Front Roll Over Analysis

Front roll over analysis is carried out to test the vehicle roll cage integrity and strength to
withstand forces in a front roll over scenario. Roll over is phenomenon can occur in case of sudden
braking cases due to momentum of vehicle. For this, around 1.5G force is evenly distributed on
the front top portion nodes and the nodes on bottom side of the roll cage are fixed in displacement
as shown in figure 3.6 (a). Based on it, the simulation is performed and result of same is shown in
figure 3.6.

Fig 3.6: (a) Boundary Conditions (b). Von-Mises Stress (c). Total Deformation

3.6 VEHICLE TESTING

The vehicle is tested for following tests, later inspected for any deteriorations or problems in the
roll cage:
A. Technical Inspection
B. Water Testing as per AIS 038
C. Acceleration Testing
D. Braking Ability
E. Maneuverability Testing
F. Endurance Testing

A. Technical inspection of vehicle is performed according to BAJA SAEINDIA rules. This

consists of various design, safety aspects which should be obliged in order to sustain the rigidity
& durability of the vehicle to the required extent. This includes various checks such as roll cage

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 10

 All-Terrain Vehicle

Design & dimensions, electric parameters such as electric motor & other parts placements,
specifications of parts incorporated in vehicle design, etc. If the vehicle complies with the BAJA
SAE INDIA rules, then it can be concluded that vehicle is safe and durable.

B. Water testing is performed so as to test the isolation resistance of the electric systems with the
chassis or roll cage, as well as to check the feasibility and performance of the vehicle after exposure
to water effects. This is done on the track designed as shown in figure 15 specifically using AIS
038 standard for electric vehicles. According to AIS 038, the vehicle is tested for 2 phenomenon
Washing plus heavy rainstorm combined test and Flooding test. To simulate washing & heavy
rainstorm effects, a washing bay is designed with proper dimensions and guidelines as per the
standard as shown. Also to simulate the flooding effect, water turf is designed with 100mm depth
of water. Overall Water Turf. Washing Bay in Water Turf.

C. Acceleration test is performed with 150 feet length straight patch, where vehicle is accelerated
and the time is recorded.

D. In case of braking test, vehicle is accelerated over a distance and stopped instantaneously with
brakes and it is checked, if the wheels are locked together and vehicle stops within shortest
distance. This test is important is a case of front rollover phenomenon.

E. Maneuverability testing is performed on a specially designed track which contains sharp turns,
irregular road pattern, inclines, pylon manoeuvers, sand, ruts & bumps. The vehicle is to move
within the guide lines on the designed track within short time. The vehicle successfully tested
within this track. This testing imparts multidirectional loading in dynamic vehicle run and rigidity
of the vehicle is tested.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 11

 All-Terrain Vehicle

CHAPTER 4

RESULTS AND DISCUSSION

Based on selected material, following static and dynamic analysis are performed on roll cage.
The result of same is tabulated in table 4.1.

Table 4.1: Overall Results of Roll Cage Analysis

It can be observed that the factor of safety obtained for all the cases is above 2 which can be
considered as the roll cage is safe and suitable for loading conditions for all-terrain vehicles. Based
on CAE analysis, the vehicle prototype manufactured and subjected to many tests such as
endurance testing, acceleration, braking, maneuverability and water testing on the track designed
as per AIS 038. After testing of vehicle, the roll cage visual inspected within key areas of the roll
cage for any deterioration, irregularities, cracks or any structural failures and it is found that no
visible damage or cracks developed within the roll cage and joints.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 12

 All-Terrain Vehicle

CHAPTER 5

CONCLUSION
Two ATVs have been designed and developed, FME, UTeM. The ATVs are fabricated within
allowable budgets. The designs have been validated by stress analysis using available CAD
software. The development of the ATVs has established design for manufacturing (DFM) practice.
With further development and research, the ATVs are subjected for improvement. The
sustainability of the design and development of the ATVs depends on the material selection, design
criteria and components availability.
The use of finite element analysis is valuable for the design of any parts in current industry.
The objective of development, analysis and testing of electric ATV under various loading cases
for the safety, feasibility and economy is completed. Based on CAE analysis, a three seater electric
all-terrain BAJA vehicle developed with modifications in regular single seater Baja vehicle. The
roll cage successfully designed and analyzed with factor of safety above 2 under various static and
dynamic loading cases. Also the vehicle is physically tested under various tests without any failure.
This project provides standard procedure and guidelines for designing roll cage and all-terrain
vehicle. Also this would help to optimize the roll cage and test the strength and integrity of the
vehicle thus improving vehicle performance and driver as well as passenger’s safety.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 13

 All-Terrain Vehicle

CHAPTER 6

REFERENCES
1) Abdullah Mohd Azmana, Tamaldin Noreffendyb, Ramli Faiz Redzac,Sudin Mohd Nizamd and
Mohamed Muslim Abdul Mu’in, “Design and Development of Low Cost All-Terrain Vehicle
(ATV)”, Applied Mechanics and Materials Vol. 663 (2014) pp 517-521,IEEE.
2) Dr. K. C. Vora, Mohammad Rafiq B. Agrewale, M. M. Desai, Himanshu Mishra, Omkar
Narkar, “Development, Analysis and Testing of an Electric All-Terrain Vehicle”, IEE
Transportation Electrification Conference (ITEC-India), 2017
3) Richard A. McKinney, Malcolm J. Zapata, James M. Conrad, Thomas W. Meiswinkel,
Siddharth Ahuja, “Components of an Autonomous All-Terrain Vehicle”, 2010 published by
IEEE.
4) M. Richier, R. Lenain, B. Thuilot, C. Debain, “On-line estimation of a stability metric
including grip conditions and slope: Application to rollover prevention for All-Terrain
Vehicles”, International Conference on Intelligent Robots and Systems, IEEE/RSJ, 2011, pp.
4569 - 4574.
5) N. Bourton, R. Lenain, B. Thuilot, P. Martinet, “An active anti-rollover device based on
Predictive Functional Control: application to an All-Terrain Vehicle”, IEEE International
Conference on Robotics and Automation, 2009, pp. 1309 - 1314.

DEPARTMENT OF MECHANICAL ENGINEERING, MITE, MOODABIDRI Page 14