Use of Additive Manufacturing in Design of Gearbox for All-Terrain Vehicles

This study includes the design, analysis and prototyping of an all-terrain vehicle (ATV) gearbox (a reduction gearbox). The gearbox used in the ATV runs on a rugged and rough terrain in competitions like BAJA SAE India, Mega ATV Championship conducted at Pithampur off-road track and Goa respectively. The main aim of this research is on optimizing the gearbox to improve performance parameters like torque, weight, and durability in harsh conditions. This chapter includes calculations for gear ratios, center distance thickness, etc., and material properties along with their selection. 3D printing technology was used for rapid prototyping, which allowed quick understanding of the motion of the gears if they have any interference during free moment. Gearbox performance was assessed in various competitive scenarios, demonstrating various significant improvements, which helped to improve vehicle acceleration and handling. The findings helped with innovative design strategies offering valuable insights for future ATV development and engineering projects.