International Journal of Innovative and Emerging Research inEngineering Volume 3, Special Issue 1, ICSTSD 2016 Design and Analysis of Go-Kart using Finite Element Method Harshal D. Patil Saurabh S. Bhange Ashish S. Deshmukh Research Scholar, Research Scholar, Research Scholar, Mechanical Engineering Department, Mechanical Engineering Department, Mechanical Engineering Department, Prof. Ram Meghe Institute of Prof. Ram Meghe Institute of Prof. Ram Meghe Institute of Technology & Research, Badnera, Technology & Research, Badnera, Technology & Research, Badnera, Amravati. Amravati. Amravati.
[email protected] Abstract— There are many motor sports in the world. Bikes, and subjected to analysis using ANSYS FEA software. Based on Cars, Formula one are examples of them. But there are also motor analyses result, the model was modified and retested and a final sports which do not need professional drivers and need no great speed. The vehicles used are also very cheap. Such a motor sport is design was frozen. The design process of the vehicle is iterative Go-Karting. Go-kart is a simple four-wheeled, small engine, single and is based on various engineering and reverse engineering seated racing car used mainly in United States. This paper explain processes depending upon the availability, cost and other such the designing and fabricating a sound kart having high fuel economy factors. The entire kart is designed by keeping in mind that it and maximum driver comfort and compactness without compromising on kart performance. This research also includes should be able to withstand the racing conditions without failure. designing kart for the performance and serviceability. Compliance Combining this design methodology with the standard with the rulebook of NKRC 2015 is compulsory and governs a engineering design process enabled us to achieve a perfect match significant portion of the objectives. This report describes in detail of aesthetics, performance, and ease of operation. the parameters included in the entire design and considerations made for zeroing those parameters. Validation of the design is done by conducting theoretical calculations, simulations and known facts. Table 1- Specifications of kart Analyses are conducted on all major components to optimize strength and rigidity, improve vehicle performance, and to reduce Roll cage complexity and manufacturing cost. The design has been modelled in CATIA V5R21, the analysis was done in ANSYS 14.5 and simulation Weight 23 kg in ADAMS14. Keywords— Go-kart; design; analysis; safe. Material AISI 1018 I. INTRODUCTION Outer diameter 25.4 mm A Go-kart, by definition, has no suspension and no differential. They are usually raced on scaled down tracks, but Thickness 2 mm & 1.65 mm are sometimes driven as entertainment or as a hobby by non- Engine- Bajaj Discover 125 ST professionals. Karting is commonly perceived as the stepping stone to the higher and more expensive ranks of motor sports. Displacement 124.7 cc The design of standard Go-karts leads to more costly production and are only manufactured for entertainment point Max. Torque 10.8 Nm of view, cannot be raced in competitions. So there is need of such a design of Go-kart that can be used for both Rated Power 8.1 Kw entertainment purpose and in racing competitions. The main aim to design a Go-kart having better performance than that of Vehicle Dimensions standard Go-karts but at lower cost. Wheelbase 42” Like every automobile, go-karts also have various Trackwidth 40” systems. Mainly there are 4 systems in this kart like Chassis, Steering, Engine & Power train and Braking. The standard Go- Overall Length 67” karts are usually powered by either 2-stroke or 4-stroke petrol engines. These engines are generally air cooled with or without Overall Width 50” gear box. Go-karts are equipped with disc or drum brakes. The vehicle has been designed conducting extensive research of each Ground Clearance 1.97” main assembly and components of the kart. We approached our design by considering all possible alternatives for a system & Steering modeling them in CAD software like CATIA 551 Special Issue 1.19 m/s2 Overall weight 97 kg II.29 m Braking Type Rear Hydraulic Disc diameter 170 mm Performance Target Max. Acceleration 1. The cost.Design parameters strengthens as well as good manufacturability. results found that two materials AISI 1018 and AISI bumpers are so designed that they will serve as protection from 1020 which are having similar properties. ICSTSD 2016 Type 4 bar geometry Turning Radius 2. For and high strength to weight ratio. of welds 34 Density 7870 kg/m3 Pipe Length 19 m Strength to Weight Ratio 60 KN-m/kg 552 . relatively soft and Table 2. the side bumper. Deceleration 11. use variable thickness pipes in order to reduce the weight of chassis.18 m/s2 Figure 1. Front Track Width 40” AISI. The objective of the chassis is to encapsulate all Figure 2. The roll cage is designed to meet the technical requirements of competition. give a rigid support for the assembly of sub systems. primary and secondary members. A. In this design. the front The selection of material for chassis is done by and rear bumpers. Rear Track Width 42” Height of RRH 45” Table 3. International Journal of Innovative and Emerging Research in Engineering Volume 3.Chassis CAD model Max. But prefer to use front and rear and will also add impressive look to the kart. 2 mm and 1. The material AISI-1018 is used in the chassis design because of its good weld ability. battery detailed study of properties of material regarding strength and cover and firewall as per the specifications in the rule book.Properties of material Outer Diameter 25.Chassis PVC prototype components of the kart.65 mm thick pipes are used respectively. engine and drive train. because of its higher yield strength the bends are of constant radius.4 mm Ultimate Strength 420 MPa Thickness 2 mm & 1. All AISI 1018 over AISI 1020. fire extinguisher. including a driver.65 mm Yield Strength 310 MPa No. ROLL CAGE DESIGN The primary function of roll cage is to protect the driver.1018 has chosen for the chassis because it has structural properties that provide a high strength to weight ratio. Speed 59 kmph Max. Material Proper numbers of members are used in the roll cage to ensure complete driver safety. efficiently and safely. These include the rear roll hoop. A good strength material is important in a roll cage because the roll Wheelbase 42” cage needs to absorb as much energy as possible to prevent the roll cage material from fracturing at the time of high impact. 7 KN B. Front impact was calculated for an 553 . Load was applied at rear end of the chassis while constraining front end and king pin mounting points.Frontal Impact No.Vf) Phosphorus P = 0.4 MPa Factor of Safety 2.38 .5 software.38 -0) at respective points.017 % F x t = m x (Vi .2 seconds Silicon Si = 0.2 seconds as per industrial standards.81 % F=14.The load cases simulated were frontal impact. Finite Element Analysis Structural integrity of the frame is verified by comparing the analysis result with the standard values of the material. side impact. engine and driver load was given F x 0. The test results showed that the deflection was within the permitted limit. ICSTSD 2016 Elongation 15% optimum speed of 60 kmph. International Journal of Innovative and Emerging Research in Engineering Volume 3. Figure 4. Welding The material which is used AISI-1018 has good weld ability.73 % approach of analysis. Special Issue 1.2 = 180 x (16. Carbon C = 0. of Nodes = 353049 Deformation 1. Time of impact considered is Figure 3. F x t = m x (Vi-Vf) Front Impact For the front impact.the metal being weld). results in a more conservative Manganese Mn = 0. 5g force has been calculated. From impulse momentum equation. of Elements = 176790 Max. The loads were applied only at The chemical composition of material is .18 % while constraining the other. Meshing Auto meshing has been done in ANSYS 14. To conduct finite element analysis of the chassis an existing design of chassis was uploaded from the computer stresses were calculated by simulating three different induced load cases . faster welding speed and is clean and efficient makes welding easier. Figure 5. Time of impact considered is 0.7 KN wheels position kept fixed.2 = 180 x (16. MIG welding uses an arc of electricity to create a short circuit between a continuously fed anode (+ the wire fed gun) and a cathode (.04 Rear Impact Considering the worst case collision for rear impact. Analysis was conducted by use of finite element analysis FEA on ANSYS software. The value of 5g force has been calculated. front end of the chassis because application of forces at one end. and rear impact.18 % as per industrial standards. The kingpin mounting points and rear F=14.Auto meshing in ANSYS 14. force is calculated as similar to front impact for speed of 60 kmph. Sulphur S = 0. It provides strongest welds.Deformation C. Stress 209. All welds on the vehicle are made using a MIG (metal inert gas) welding process.47 mm No.5 0.020 % F x 0. MIG is selected because it provided the best control of heat affected zones while also reducing internal stress in the frame selected in order to allow the weld to flex slightly without cracking.0) Iron Fe = 98.Equivalent stresses Following data has been found after meshing of chassis – Table 4. The maximum frequency of chassis vibration is nearly Side Impact 100 Hz and the results of analysis have been shown below.19 -0) F=7.Rear Impact Max. So it was the resonance will not occur.Deformation Figure 6.Equivalent stresses Table 6. Stress 277. Special Issue 1.5g force on the right side.Side Impact Figure 7.5 MPa Deformation 2.71 MPa Factor of Safety 1.35 KN Figure 10.2 = 180 x (8.74 mm Factor of Safety 1.2 seconds as per industrial standards. For the side impact the velocity of vehicle is taken 30 kmph and time of impact considered is 0.17 Max.Equivalent stresses Deformation 1. International Journal of Innovative and Emerging Research in Engineering Volume 3. assumed that neither the vehicle would be a fixed object. Stress 302. So side would be with the vehicle already in motion.73 Modal Analysis Modal analysis was carried out for chassis and frequency of vibration was found to be less than desired engine frequency.Modal analysis 554 . F x t = m x (Vi-Vf) F x 0.Deformation Figure 9. The The most probable condition of an impact from the minimum frequency of vibration for engine is above 800 Hz. ICSTSD 2016 Figure 8. Impact force was applied by constraining left side of chassis and applying load equivalent to 2.46 mm Table 5. And thus design is safe. Analysis results it reduces the steering efforts.2g magnitude and kingpin movement were applied Therefore from above condition to respective points while constraining the stud in all the θo = 26.14 mm linkage system has been used to make steering simple to manufacture. requires low maintenance. Stress 62. International Journal of Innovative and Emerging Research in Engineering Volume 3. Special Issue 1. Ackerman steering mechanism has been selected for steering Figure 14. decrease the steering effort and the amount of Max.29 m 555 .54o directions. θi = 38o The AISI 1040 steel has been selected for the design Wheelbase (b) = 1067 mm of stub axle.Graph of frequency Figure 13.97 MPa steering wheel travel and increase the steering responsiveness. Along with controlling the vehicle. Now. For worst condition.83o Turning Radius ( R ) = ( b / sin θo ) − length of stub axle Therefore R = 2. the steering system has to provide good ergonomics and be easy to operate.Equivalent stresses system because it does not slip during the turning of tires and Table 7. the deformation and stresses are as follow.CAD model of steering b – wheelbase Stub Axle Assuming. Force equivalent to load of front tires. The main goal for steering is to have steering radius of 4m or less. α = 19. cornering King pin distance (c) = 769. STEERING SYSTEM The steering system for the vehicle has to be designed to provide maximum control of the vehicle. Simplicity and safety were the main design specifications for the vehicle’s steering system.Deformation III.41 Steering Calculations The Ackerman condition is expressed as Cot θo − Cot θi = c / b Where. Ackerman angle (α).72 mm force of 1. Mechanical steering Deformation 0. ICSTSD 2016 Figure 11. After researching multiple steering systems. Factor of Safety 3. The positive 3 degree caster is given for self centering of the kart. the four bar steering type was selected which provides easy operation. tan α = king pin distance / ( 2 x wheelbase ) therefore. less weight. θo − outer steering angle θi − inner steering angle c − distance between king pin Figure 12. provides excellent feedback and is cost effective. According to rule book of NKRC 2015 the vehicle travelling at 40 kmph should stop when you apply the brake. the driver must have complete control of the vehicle while brakes are King pin distance 769 mm actuated. Min.11 Table 10.54o demands. the brakes have been designed to lock up rear wheels.Braking system Table 9.66 Nm vehicle beside the steering column for easy maintenance. outer angle 26. Moreover.Graph of steering angle Pedal Force Applied 100 N Pedal Ratio 6:1 Velocity 11. ICSTSD 2016 Table 8. Special Issue 1. The disc is mounted on the rear axle as shown in figure below. International Journal of Innovative and Emerging Research in Engineering Volume 3. In order to Wheelbase 1067 mm achieve maximum performance from the braking system.Steering parameters The objective of Braking System is to provide reliable and prompt deceleration of vehicle.Calculated values Force generated by caliper 957. Max.3 N Figure 16. Figure 17. turning radius 2. inner angle 38o which is operated by 2 piston calliper hydraulic braking system.83o King pin inclination 5o Length of steering arm 100 mm The simulation of steering geometry has been done in ADAMS 14 and the inner & outer steering angle were calculated from it. BRAKING SYSTEM Effective radius of disc brake 0. The disc of diameter 170 mm.Braking parameters Brake Type Hydraulic disc brake Rotor Diameter 170 mm TMC Diameter 19 mm Caliper Piston Diameter 24 mm Rotor Thickness 4 mm Figure 15. while Front track width 964 mm minimizing the cost and weight. Master cylinder is placed front side of the Self aligning torque 35. Tie rod length 350 mm A hydraulic disc brake has been chosen as a suitable way to accomplish these requirements.122 m 556 .29 m Caster angle 3o Ackerman angle 19. has been selected according to vehicle design Max.Steering model in ADAMS IV. Engine RPM 8000 Tyres Table 11.19 m/s2 4th gear reduction 1.050 % Overall Dimensions 16. After long research work and survey.5” x 10.60 % Fuel Economy 68 kmpl Carbon (C) 0.71 Braking torque 281.47 N 2nd gear reduction 1. Power 13 PS Manganese (Mn) 0. The material used is EN8 which is also known as Rear Tyre Size 7.08 Braking force 1st gear reduction 2. ICSTSD 2016 Pressure inside TMC 2.040 % Gearbox 5 Speed The values of forces and bending moment are calculated and shown in figures below - Table 13. It is the solid shaft of Front Tyre Size 4. So the design is according to the engine specification.6 % Max.Tyres specification Shaft Design Tyre Used Slick Tyres The rear axle is used to transmit the power from engine to the rear tire through chain drive.8 Nm Iron (Fe) 98. It is the medium carbon steel with improve strength over mild steel and it is easy to machine at supplied Rim Diameter 5” condition. So there had number of options for the selection of Ultimate tensile strength 620 MPa engine such as Honda shine.40 % Dry Weight 22 kg Sulphur (S) 0.11 MPa Primary Gear Reduction 3. It have inbuilt gear box of manual 5 speed constant mesh gear box.83 3829.33 Deceleration 11.Gear reduction values 557 . Density 7.44 Nm 3rd gear reduction 1.08 Stopping distance 5th gear reduction 0.EN8 properties V ENGINE POWER TRAIN Mechanical Properties A single cylinder four stroke 125 cc engines is selected.1/5-11 AISI 1040. it is decided to use Bajaj Yield strength 415 MPa Discover 125 ST engine to power a kart.5” x 12. Torque 10.91 2.75 m Max. Bajaj discover.5/5-10 diameter 30 mm and length of 42” according to design calculations.845 g/cc Table 12.Engine specification Youngs modulus 210 GPa Engine Bajaj Discover 125 ST Chemical Composition Max. The specification and the properties of the material is given below. International Journal of Innovative and Emerging Research in Engineering Volume 3. Table 14.12 N Frictional force 2297. TVS Phoenix etc.5” Phosphorus (P) 0. with the multi Hardness 58 Rockwell plate wet clutch. Special Issue 1. chain drive type transmission is most preferable as it is easy to install. emission. the diameter of the shaft is found to be 28.Chain drive according to application and power of engine.7 mm use of more rounded corners than the straight. engine bays. to meet local regulations and application requirements.07 mm Driven Sprocket No of Teeth 36 Pitch circle diameter 145. So the diameter of the shaft is taken as 30 mm.57 Diameter of shaft 30 mm Driving Sprocket Figure 18. reducing exhaust noise secondary reduction ratio. Special Issue 1. ICSTSD 2016 Length of chain 685. the chassis design is improved by the Chain pitch 12. After interpreting the chain data. 1. International Journal of Innovative and Emerging Research in Engineering Volume 3. Aesthetically.72 mm Figure 19. numbers of teeth on driving sprocket are decided Figure 20. Providing adequate clearance between exhaust Table 15.51 mm Gear Ratio 2. Max. machine Chain structures.25 Aesthetics Chain no 8B The kart is so designed that every sub-system is visible from outside.Specification of chain drive system components and engine components. torque at rear axle 242 Nm VI SUPER STRUCTURE Shock factor 1. enclosures to reduce the impact of high exhaust temperatures on such systems. 558 . Chain Drive For this system. The unique use of rounded corners allows for a more pleasing look to the vehicle’s body as well as a reduced number of welded joints.5 mm No of Links 54 links Roller diameter 8. From the the limits specified for the particular engine model and rating analytical calculations. simple in design and cost effective.01 mm.Load diagram No of Teeth 14 Pitch circle diameter 57.71 is the tabulated value of to provide maximum efficiency. The secondary gear reduction is calculated on the basis of how much Exhaust System maximum rpm driven sprocket should possess in order to run The design of exhaust needed to be in such a way that the kart at top speed of 60 kmph considering the transmission it should be lighter in weight and should have minimum efficiency and manufacturing deficiencies and how much resistance to gas flow (back pressure) and keeping it within maximum rpm is available at the driving sprocket. The chain type used is of roller chain and pitch of chain is decided from power rating table.Bending moment Using above values. Ease of egress is less than 3 seconds. but may also have a positive effect on the overall aerodynamic drag forces. Rear roll hoop is incorporated in order to protect the driver in case of rollover of kart. Starter. The gear shifter is placed on left hand side of driver and is easy to operate. Electricals In this Go kart. Figure 22. Figure 24. The kill-switch which is mounted near the front side of seat is in ease of access to the driver in case of emergency.Front View The following figure shows the driver’s sitting posture - 559 . ICSTSD 2016 The use of continuous bended pipes also reduced the no of joints. Tail lights and two kill switches. 12V . the lack of sharp edges on the chassis frame allows for the design of more streamlined body panels which not only look smoother. This kart has compact cockpit which is comfortable yet safe. which is clearly seen by rear vehicles.Isometric view The seat in this kart is designed to be very light and is made of plastic material. The fire extinguisher is on right side of driver and clamped to firewall. VII ERGONOMICS AND SAFETY Figure 23.Driver ergonomics When the panels were integrated into the car. the panels were recessed into the chassis to provide visibility to the chassis members. The pedal position is ergonomically compatible with the driver’s driving style. It is attached to the chassis by four points along with rubber bushes to reduce vibration to increase driver’s comfort. one can use the kill switch which is placed on the right of the driver to kill the engine. Ignition system. International Journal of Innovative and Emerging Research in Engineering Volume 3. The parallel circuits from battery are connected to the electrical appliances such as. In case of accident. The steering wheel is designed so as to occupy less space and easy to steer. in order to reduce the weight of kart making the car aesthetically pleasing. Brake light is mounted on the rear end of the chassis. yawing from side and also helps to create the downward force to which tends to make the good traction of vehicle with the road & also provide the properties necessary to protect the driver and vehicle components from rocks and other debris. Body Panels The panels are designed such that they tends to reduce the aerodynamic moments like pitching from front. The green coloured body panels made up of fibre material is used. Special Issue 1. These switches are located near front side of seat and other at the right side of the driver on the rear roll hoop.5 Ah battery is used. 2015). ICSTSD 2016 This paper gives adequate idea and design guidelines about modeling of Go-Kart. University Figure 26. V (Nov. Volume 12. Nagaraja.JagadeeshVikram. It is also suitable for Analysis of GoKart Chassis by Analytical and Solid Works Simulation”. pp: (73-78). maximum deformations. ISSN No. Kulkarni. Engineering and Technology.4.com [7] Muhammad Bin Zulkifly. 3. S. chassis design is safe. Kirpal Singh.3 Issue No. “Design and Fabrication of a GoKart”International Journal of Innovative Research in Science. “Preliminary Design Report. Hence the Dynamics” Society of Automotive Engineers Inc. May. Thus after all the analysis and design calculation. fourteenth edition. 2005 of Safety and its location on chassis model.March 2016. September 2015. Iss.: 2319-8753. International Journal of Mechanical and Industrial Technology.org. Mirza Shahrukh. Vol. R. (ISSN : 2277- 1581).academicjournals. Result concluded that the AISI 1018 material is more [9] Rahul Thavai.researchpublish. “Static analysis of Go-Kart Chassis frame by Analytical and SolidWorksSimulation”.org/SRE [4] Aniket Mind. “Design and fabrication of a student competition based racing car” Scientific Research and Figure 25. Factor Publications house pvt.Side View Malaysia Pahang. International Journal of Scientific Engineering and Technology.Top View Essay Vol.Vol. References [1] AritraNath. Eurasia determine equivalent stresses. [6] Mr. Ravichandra R. [8] Xiang Liu. C. 361-366.5. person driving it. speeds. 4. Standard Publishers Distributors. Quazi Shahezad.p- ISSN: 2320-334X. NGKC 2014”.ISSN 2348-7593 (Online). Khurmi. “Design and Fabricate Braking system For the Electric Buggy Car”. article in Archive Proceedings of the Institution of Mechanical Engineers part C journal of Conclusion Mechanical Engineering Science 1989-1996 (vol. D. International Open Access Journal of large scale production. International Journal of Innovative and Emerging Research in Engineering Volume 3. 4 (5) pp. 2015. “Fabrication of a Model Go-Kart (With Low Cost)” Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684. Gillespie. [3] A. - Dec. Publications. Special Issue 1. [12] John B.iosrjournals. 2009 ISSN(online):1992-2248 © 2009 Academic Journals. “Automobile Engineering vol-1&2”. “Static Analysis of a Go-kart Chassis” . Month: October 2015 . pp : 661-663. It concluded that our design of Go-kart is safe for fabrication using healthy manufacturing practices. Heywood. carrying the load of single Vehicle Dynamics”. method was successfully carried out on chassis CAD model to Apr. “Fundamentals of Vehicle safety calculated is found to be greater than 1. 1 May 2014. Milliken. Faieza. Publications. www. Mc Graw Hill Inc. Static analysis using finite element Modern Engineering Research (IJMER) Vol. Pune [5] N. Ltd. Issue 2. C. [2] Dr. Also the Steering system designed for the kart gives the turning radius which satisfies the minimum condition of turning the go-kart on racing tracks. “Static economic and gives better performance. Ravikanth . Milliken and Douglas F. November 2007. 560 .” Design of an Ackermann-type steering Mechanism”. Sinhgad Academy of Engineering .Team Nexus Racing. “Internal Combustion Engine The Engine selected and Power train designed can easily Fundamentals”. Milliken Research Associates Inc. “Race Car propel the Go-kart at higher speed. “A Textbook of Machine Design”. The Factor of [11] Thomas D. Issue 9. 5. GirishMekalke. The Brake system is also designed so as to Publications lock the rear wheels and stop the kart safely even at higher [14] Dr. PP 24-30 www.203- 210) November 2013. Patil. A. [10] R. www. [13] William F. Issue 6 Ver. Volume No.