ABSTRACTThe objective of the ELITE KARTING INTERNATIONAL GO KART team is to ace the EK14 GO KART INDIA 2014 by designing and manufacturing an go kart delivering optimal performance while conforming to high safety, durability, maneuverability within the set cost and size restrictions. The vehicle was designed and analyzed using SOLIDWORKS13. The team focused on improving every single system on the car to boost performance.

INTRODUCTIONSTEERINGTo design a steering system in a go kart there should be a proper ackerman %, caster trial, scrub, average steer angle, tie rod length, king pin angle, caster and chamber angle to maintain the less steering effortBRAKESThere should be the proper pedal ratio that can multiply the force given by driver. A proper transmission of fluid from the master cylinder that will transfer all the force applied by the driver to the caliper and stop the rotor. POWER TRANSMISSIONTransmission requires the proper sprocket ratio to move the whole vehicle while accelerating.TYREWe are using a tire of 10 inch dia and 6 inch width.CAD DESIGNINGTo design a go kart there should be a proper frame designing that can hold the whole chassis weight and as well as driver weight and has the ability to endurance forces. Which is done by simulation in solid works.MATERIAL SELECTIONWe are using various material for different component according to there usage. Also the best suitable material that should have strength, rigidity, cheap and also lighter weight which makes the car more faster.

DESIGN OF VEHICLEThe design of our go kart is broken in to four major parts(1) The design objectives (2) The design calculations and analysis

(3) Considerations

(4) Testing

Based on the overall design objectives of durability, performance, and light- weight design, the component is evaluated by the design team and must meet all of the criteria to become a part of the overall successful design alternatives were also considered during each process and testing commenced once the chosen design met the design objectives.

FRAME DESIGNOBJECTIVE The frame is designed to meet the technical requirements of competition the objective of the frame design is to attach all the various components of the chassis, keeping narrow from front for low turning radius and also for extremely rigid so that it can with stand shocks . Principal aspects of the chassis focused on during the design and implementation including driver safety, drive train integration, and structural weight, and operator ergonomic. The number one priority in the chassis design was driver safety. By the competition rules and Finite Element Analysis (FEA), the design assured. DESIGNThe main component of the frame are divided into the two major parts first the front block (cockpit) for steering and seat positions etc. and second rear block (engine compartment) for transmission and brake assembly. Both the blocks are separated by the firewall(FIRE WALL DIMENSION).

The frame modal can be viewed as shown below

Isometric view

MATERIALThe material AISI4130 is used in the frame design because of its good tensile strength of 560Mpa and strengthens as well as goodmanufacturability. A good strength material is important in a frame because the frame needs to absorb as much energy as possible to prevent the frame material from fracturing at the time of high impact. AISI 4130has structural properties that provide a low weight to strength ratio. 26.9 mm diameter tube with a thicker wall is used instead of 1inch diameter tube with a thinner wall for manufacturability purposes. Although the thinner wall, 1 inch diameter tube would be slightly lighter than the thicker wall, 1 inch diameter tube, it would have been more material, more difficult to weld and also low strength. Then it is also assured by analysis in SOLID WORKS software. The various Physical properties of the material are as follow.

PropertiesValues

Tensile strength,ultimate560Mpa

Tensile strength,yield460Mpa

Bulk modulus140Gpa

Shear modulus80Gpa

Modulus of elasticity210Gpa

Poissons ratio0.27-0.30

Elongation at break21.50%

Hardness brinell217

Hardness Rockwell95

above mentioned properties satisfy the technical requirement of material which is to be used in frame. SAFETYFrames feature were first implemented bykeeping on mind the safety requirement of the event .The first primary safety standard focused on during design was maintaining the proper clearance of the drivers body rest to the other rigid parts like engine compartment, firewall structure, and panel bracing of the vehicle. Once the basic requirements fulfilled the other safety design were implemented. The chassis was designed to give occupant extra space to operate the vehicle easily. Also proper seat belts are arranged in the seats for drivers safety. The place of the fire extinguisher is designed in the easily accessible point.

FRAME FEA SAFETY ANALYSIS Aside from exceeding the minimum material requirement set by the discussion in team members. Structural integrity of the frame was verified by comparing the analysis result with the standard values of the material. Theoretical calculated loads were placed on a wireframe model of the frame at critical points to simulate the amount of force that the vehicle would undergo from its own weight and the driver in the event of collision. Analysis was conducted by use of finite element analysis FEA on solid workssoftware. 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 .The load cases simulated were frontal impact, side impact, and rearimpact, A 4-node quadrilateral (Quad4) shell type element was used when developing the mesh to model the hollow tubing the value of the force in different cases of impacts is calculated by the procedure as follow

FRONT IMPACT ANALYSIS Generally in the case of pure elastic collision in front impact the linear velocity remains at 55Kmph .here the value of force is calculated by mass moment equation that is-

F= PT

Where T is the duration of time, generally the collisiontakes place for a very short duration of time. We will assume the time as T =1.10And the gross weight of the vehicle is Estimated some around (M=130kg), hencethe velocity of the vehicle at 55Kmph or 15.2m/s. Now the calculated force were placed on the frontal part of frame by keeping the rear part fix on SOLIDWORKS the result along with the image as

SIDE IMPACT ANALYSISIn the case of collision by side impact the value of the impact force generated is calculated in the same way as in front impact. For the side impact the velocity of vehicle is taken 55kmph or 15.2m/s1500N were placed on one side of the modal of frame while keeping another side fixed and the stresses were simulated the image is shown as

REAR IMPACT ANALYSIS The rear impact force is also calculated in the same way as remaining two. In this case the velocity of collision were taken 55kmph or 15.2m/s by calculations.

1500N force was placed on the rear part of the frame while keeping the frontal part fixed. The analysis result is shown as

FACTORSFRONTREARSIDE

Impact force2500N2500N2500N

Stress generated6.39N/m^24.46N/m^23.100N/m^2

Total deformation 0.28mm0.228mm0.22mm

FRAME DESIGN CONSIDERATIONSConsiderationsPriorityReason

Meet requirementEssentialMust meet requirements to complete

DurableEssentialMust not deform during rugged driving

Simple framehighMajority of frame fabrication done in workshop

CostlowCar should be within the budget

Attractive designdesiredEasier to sell an aesthetically pleasing vehicle

Light weightessentialA light race car is a fast race car

STRUCTURAL RIGIDITY Overall frame structural rigidity is important to enhance the capabilities of a 4-wheeler vehicle. To measure the overall frame rigidity, tensional rigidity analysis was conducted through FEA. The objective of the tensional rigidity analysis was to manipulate the chassis design within the FEA software to increase the amount of torque per degree of chassis deflection. By theoretically increasing this value, the actual vehicle could have the ability to be more torsion-ally rigid, making it able to withstand more intensive without failure. The 2500N force is placed on one of the corner of the frame while other three corners were kept fixed by constraining. The deformation and stress were as follow for the generated stress of 9.58N/m^2.The result is displayed as

Hence according to the result obtained the frame would be torsion-ally rigid.WEIGHT Keeping the frame as light as possible was a top priority. When power is limited, vehicle weight is a large factor in vehicle performance. The frame is one of the largest and heaviest components of the car, and due to which the special attention is given on the vehicles frame weight. The strategy utilized to minimize weight consisted of determining defined goals for the chassis and employing the correct material in the best places to accomplishthose goals. Once baseline safety design requirements were met, FEA aided the material decision making process. FEA specifically helped to determine whether a member was under high or low stresses, in the scenarios discussed previously, making the chassis design process efficient and effective.there are many factor which should keep in mind while selecting the material that is(1)cost(2)mechanical properties(3)wear of materials(4)corrosionASTHETICAesthetically, the roll cage design is improved by the use of more rounded corners than the straight. The unique use of rounded corners allows for a more pleasing look to the vehicles body as well as a reduced number of welded joints. The use of continuous bended pipes also reduced the no of jointsthelack of sharp edges on the frame allows for the design of more streamlined body panels which not only look smoother, but may also have a positive effect on the overall aerodynamic drag forces.

MANUFACTURABILITY All design work for the go kart championship has done In the solid works software. Using this program to produce three dimensional model allowed easy revision of prebuilt designs, and gave design team members a visual picture of what the frame would look like. After the design of the frame was finalized, a list of required support members was created and the frame modal was modified. The design for manufacturability, ergonomics, and aesthetics for the chassis are favorable for its reproduction, serviceability, and comfort. The material selected AISI4130 has good manufacturability qualities. To increase manufacturability, many bends were used as frame members. These bends not only give the vehicle a sleek, attractive look but also reduce the total amount of frame members and welds between these members resulting in a lighter, cheaper, and customized chassis. By implementing bends into the design of the frame, the number of cuts and welds were decreased. Decreasing the number of cuts and welds lowers the production cost and increases overall chassis strength. For example, by using more bends, A bending die can perform the job of bending behalf of the welding and joining hence reducing man-hours and production costs. All bends were designed to be made using a tube bender.WELDING - The material which is used AISI 4130 has good weld ability so we will going to use MIG welding and arc welding because arc is the only welding used for steel in which specific electrode are used.ERGONOMICSTo set the most suitable ergonomics for our go kart we have to set such dimensions that should have the best comfort posture for maximum driver.

DESIGNTo design the ergonomics we have to calculate all the angles between the all the joints and seat from vertical in such a wayso that our driver is in the best comfort posture, the design is mentioned below-

STEERING SYSTEM (innovation)

OBJECTIVEThe steering system is designed to withstand the stress of safelymaneuvering the vehicle through any type of possible condition at the time of driving. The purpose of the steering system is to provide directional control of the vehicle with minimum input. The main goal for steering is to have steering radius of 4m or less and to have 100% Ackerman steering and the adjust ability of the steering for any person driving a go kart.

DESIGNSimplicity, safety and adjustable steering were the main design specifications for the vehicles steering system. While designing the steering system the constraints that we possessed were center alignment of steering system, track width, human effort at the steering wheel and the desired response of the steering system. A Pivot Pin steering arrangement was chosen due to its light weight, simple design and low cost. Very less play due to limited number of joints. We are also introducing the adjustable steering system according to this there is a modification in simple steering system in this there are two column are used having different radius the column with a greater radius should be hollow one and 6 or 7 drill will be there at specific distance on both the column for the up and down motion also for too and fro motion there is a u-v joint between the lower radius column and steering bush , the supporting arms are connected with T-shape which is weld with the column. The T shape joint have a slot to attach the supporting arm and also helps in motion of it.Caster=12King pin inclination=12Camber =0.

Design

Above design full fill all the condition required for the steering.

Prototype of an adjustable steering

CALCULATIONSWe have turning radius,c (track width)=990.6mm,b(wheelbase)=1447.8mm

TR= track width + wheel base 2 Sin (avg. steer rate)TR = 47 + 57 = 88.48inches = 2247.3mm = Y 2 sin (45)

Wheel base=1440mm track width=1193.8mmtanA=b/(Y-c/2) inner wheel angletanB=b/(y+c/2)outer wheel angletanA=1440/(2247.3-586.9)= 1440/1660.4=0.876tanA=0.87 A= 40.69tanB =1447.8/2834.2=0.51tanB=0.541B=28.36for 0king pin and 0casterScrub radius=z=x^2+y^2X=caster trail=6.664mmY=scrub distance=132.08mmScrub radius=132.24mmN on one tire=22.75x10=227.5NTorque at steering=0.6x227.5x0.132Torque at steering arm=18.010Nm Torque=fx3xsin(45)F=18.010/66=272.87NTorque on steering bushTorque=r2xf=136.435Nm on bush Steering effort=136.435NmAckerman %

Error=0.0199.99% ackerman conformation of the ackerman on solidworks

Steering specifications- Various calculations are tabulated as follow according to the vehicle specifications

Inner Turning Angle 40.69

Outer Turning Angle28.36

Turning Radius2178.5

Caster Angle12

Camber Angle0

King Pin Inclination12

Tie Rod Length14inch

Steer Wheel Diameter12inch

Ackerman%99.99%

STEERING DESIGN CONSIDERATIONSConsiderationsPriorityReason

Simple designHighA single unusual change can create a problem

Ackerman geometryHighFor perfect stering on turn

BRAKE SYSTEM

OBJECTIVE The purpose of the brakes is to stop the car safely and effectively. In order to achieve maximum performance from the braking system, the brakes have been designed to lock up rear wheels, while minimizing the cost and weight. DESIGN The brake system design includes the single disc at the rear axle to stop the vehicle. It is mounted in the one third part position of the axle with opposing the position of drive train sprocket hence also enables the good balancing requirement. Master cylinder is used at the front near the brake pedal providing the occupant to easily accessible space. A proper master cylinder bore size was found by doing brake calculations based on the mass, center of gravity, master cylinder volume size, and various dimensions of the vehicle. Though braking power increased with a decrease in bore size, the volume of brake fluid that was able to be displaced decreased with decreasing bore size.

BRAKE SYSTEM CALCULATIONSTotal mass(driver+go kart)=140kgWeight distribution Front=35% and rear=65% Normal force on front tires(MXgX35%)=140X9.8X0.35=480.69NNormal force on rear tires(MXgX65%)=140X9.8X0.65=891.8NFrictional force on front tires(XNfront)=0.7X480.69=336.48NFrictional force on rear tires(XNrear)=0.7X891.8N=624.26N

Deacceleration=total frictional force Total mass=(336.483+624.26)/140=6.86m/sec^2Stopping time=v/a=12.5/6.86 (45km/hr)=12.5m/sec =1.82secStopping distance=s=v^2/4a=5.69mFluid pressure=FpXRX/A=242.669X10^4N/m^2 Area of cross section of master cylinder(A)=1.978X10^-4m^2Area of caliper(Ac) =1.548X10^-3m^2Clamping force-=FpXAc=3756.52N/m^2Frictional force between pad and disk=XCf=1502.608NDistance of caliper with centre of moving axle=0.0625m^2Braking torque=1502.608X0.0625=93.913NmBraking effort=braking torque/radius of tire=93.913/0.127=739.472NBraking efficiency=(total weight of car /braking effort)X100=18.93%Weight transfer=total weightXdeacclerationXheight of cog(0.015m) Wheel base =97.61NDynamic load on front wheel during braking=static front load+weight transfer =49X9.8+97.61=577.81NDynamic load on rear wheel during braking(static rear load-weight transfer)=91X9.8-97.61=794.19N

Brake specificationsdisc outer diameter160mm

Thickness of disk3 mm

Brake pedal force100N

Pedal ratio6:1

Coefficient of friction0.4

Brake line pressure24.266bar

Brake torque93.913Nm

Stopping time1.82sec

Stopping distance5.69m

Brake efficiency18.93%

Clamping force3756.52N

Having the above values the brake system will work in proper manner and will satisfy the requirement.Here is the brake line block diagram which sates the position of various parts of the brake system-

BRAKE SYSTEM DESIGN CONSIDERATIONSconsiderationsPriorityReason

SimplicityEssentialSimple braking has the ability to stop the go kart

PerformanceHighSo that go kart will stop on time

LightweightHighAs weight increases speed decreases

ReliabilityHighFor better performance

ergonomicsHighTo keep maintain the distance of 3inch

DRIVE-TRAIN DESIGN

OBJECTIVE

The drive-train is a very important part of the racing cars, taking into consideration that all of the cars power is transferred through the drive-train system to the ground. The challenge is to harness the engines horsepower and distribute it to the ground in the most efficient way. The chain drive needs to be able to operate in the lowest and highest sprockets ratios while performing in all of the different aspects of the competition.DESIGNThe goal of the chain drive is to transfer power from the engine of the vehicle to the wheels. The power transferred must be able to move the vehicle. Acceleration is also an important characteristic controlled by the drive train.Thereare several different methods of power transmission that have been used in cars. The transmission used in our vehicle is the simple chain drive system. This transmission uses two sprockets having proper teeth ratios according to the torque of an engine required to move the vehicle which hare connected via chain, the rear sprocket is connected towards the left side shaft with respect to driver which act as differential on turns this type of differential is known as DIY type differential also centrifugal clutch is connected with the engine shaft.Calculation of power tranmisionEngine torque (max)==9.4Engine sprocket size=r1=1.25inch=0.03175mAxle sprocket sizer r2=4inch=0.1016Force on drive sprocket(f1)=1/r1=9.4/1.25X0.254 =296.06N Axle sprocket torque2=r2XF1=0.1016X296.06=30.0796NRadiusof tyre=0.127mTorque on tyrw(t3)=R3XF1=0.127X296.06=37.59Nm3:1 gear ratoRpm of rear axis soprocket= rpm of sprocket 1/gear rato4500X1/3=1500Speed of go kart=1500X0.12\7X0.1047=71.8Km/hP=2XxNXT 60T=8.6X746X60 =40.8Nm 2XX1500Torque on shaft=40.8NmTorque on shaft=fXrF=40.8/0.3175=128.50NAcceleration of vehicle=F/m=128.50/150=0.856m/sec^2WHEELS The wheel is one of the main components of thewheel and axle .Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating movement or transportation while supporting a load. The selection of tires according to the requirement of performance, event, as well as bugged plays an important role. We are using the different size of our rear and front wheels . The size of the tires is 10inch diameter and 6inch widththe objective of selecting this tire is to get required ground clearance

Engine

ObjectiveTo select the engine we have to mind the amount of rpm and the torque of the engine. A proper amount of torque will allow a kart to move load initially while rpm will going to decide the speed of the kart.Selection:Engine specificationsHPMax. Power 11bhp

Displacement125 cm3

Max. Torque

10.8Nm

Type

4 Stroke, Single Cylinder, Air Cooled OHC

Engine Discover bajaj 125cc

Design Engine is mounted over the thick plates which are tightly weld with the frame engine is located in the rear part of the go kart

ELECTRONICS(innovation)OBJECTIVES The electronic system for the car was designed to fulfill two key purposes. First, the electronics system supports the mandatory safety equipment, specifically the kill switch circuit. Second, the electronics provide useful instrumentation, in particular a self start system. Apart from this there is an innovation regarding the safety in emergency which we call it as a skull technologies.

DESIGN The cars electrical system has been designed around two main power buses, each with an independently fused circuit. These buses are for safety kill switch, and self start system.

kill switchKill switch is provided in our vehicle as a safety to our driver in a case of emergency. If driver wants to stop the engine in case of emergency so he pushes the kill switch gently and our engine would stop. The electronics are designed so that when the kill switch is depressed, power is disabled on primary ignition coil of engine. Because the kill switch closes the circuit when activated, the kill switch function is achieved by using a pair of diodes to simultaneously ground out the engines primary coil current. One diode prevents the engine from grounding through the relay and the other diode prevents battery current from flowing back into the ignition coil.

Electrical circuit:

Brake lightOne brake light is to be designed on the back of the go kart which can be clearly visible to the back karts to design the brake light we should have the proper battery and a switch that will be able to put on while the driver is applying the brakeThe circuit diagram for the brake is shown below:

CONCLUSION-The Transforming dexterous team used the finite element analysis system to evaluate, create, and modify the best vehicle design to achieve its set goals. The main goal was to simplify the overall design to make it more light-weight without sacrificing performance and durability.

Refrences1). F.O.V.Dby Thomas D Gillespie2)elite karting given data3)a tune to win4)automblie engineering