Machine Design

Failure analysis

National Institute of
Technology Raipur

Failure analysis of Driveshaft in

an All Terrain Vehicle
Group 61-70

Guided by Dr. S. Sanyal

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 INTRODUCTION
A few months back some students of Mechanical
Engineering designed and fabricated an All
Terrain Vehicle.

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 video

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 Description of Powertrain
The sub system in our vehicle where the failure occurred

Disc Brake

Tires

Driveshaft

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BRAKING SYSTEM USED
Inboard braking system was used. In this type of
braking system, brakes are not attached to the
hub of the wheel but are rather attached directly
to the chassis of the car.
A calliper and disc of comparatively larger
diameter is directly fixed with final drive axle which
is braked when pedal is pressed.
Due to approximately 40%
weight transfer during
braking, inboard braking
system works well in an
off terrain run and provide
instantaneous braking. 5
 This circle is concentric with Driveshaft

Disc Calliper
When the brakes are applied, the stopping
force is exerted by calliper on the disc and the
driveshaft tends to stop.
But the wheel are still rotating due to inertia 6
 AB is a solid shaft which is receiving the power
at 1.
The power received at 1 is equally distributed
to both the wheels.

Disc Brake

1
Tires
A B
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Failure in driveshaft

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 When the brakes are applied, the stopping
force is exerted at 2
But wheels still have the tendency to rotate
due to inertia

Disc Brake
Tires
1
A
B
2 9
 Disc Brake
Tires
1 2
A
B

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 Due to this, the failure occurred in between 2
and B ie at C

Disc Brake

Tires

1
A
B
2 C
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FAILED SHAFTS

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 REASON OF FAILURE
According to our observation, the driveshaft
failed because of the TORSIONAL shear stress.
Since at 2 the brake is applied to stop the
rotational motion, a part of driveshaft at 2
tends to stop

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 whereas a part of drive shaft which is near to
B is still in the motion and is opposed by the
force applied at 2
Due to this a torsional moment is created
between 2 and B.

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 REASON OF FAILURE
The diameter of shaft was not larger enough to
withstand shear force applied during the inboard
braking of an ATV.
And this limit of resistance might have exceeded the
strength of the drive shaft due to which it resulted
into the failure

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 REASON OF FAILURE
The diameter of rotor disc used for braking is
bigger than required, thus implementing a
larger resisting force than necessary.
Inappropriate material used for driveshaft

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 MODIFICATIONS SUGGESTED
Optimum diameter of driveshaft.
Optimum diameter of Brake disc.
Optimum amount of force to be applied on
the brake disc.
Usage of outboard braking system rather than
inboard braking system.
Use of suitable driveshaft material.
Not aggressively braking at higher speeds.
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THANKYOU

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