Design, Synthesis, and Manufacturing of a Competitive Lightweight, Space-Frame, Open Wheeled, Single Seated All-Terrain Vehicle

Abstract

The process of designing a vehicle isn’t a simple task. The procedures of designing a safe, reliable, high performance, lightweight, space-frame, and single seated All - terrain vehicle (ATV) through applying the necessary scientific tools, engineering knowledge, and skills are highlighted in this work. An ATV was designed according to specific rules predefined by the Society of Automotive Engineering (SAE) board to ensure a high level of safety during the execution of different steps. The project was created with the idea that the best way to learn engineering is by doing engineering, where the vehicle described in this project is the result of the integration of several junior and senior engineering design projects. An innovative steering system design is introduced, including mathematical optimization of an inverted Ackerman steering system linkages. Experimental testing of suspension system components took place, and for improving ride comfort, anti-dive and anti-squat mechanisms were implemented. The vehicle was designed mainly for endurance purposes, so more attention was drawn to components’ durability and frame rigidity to sustain the severe conditions of stress arising from typical off-road driving obstacles (sand, mud, gravel, stone, dirt,...etc.), in addition to driver comfortability to secure sustainable driving as much as possible on rough terrains.