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    Design Report of A Go Kart Vehicle

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    Shaik Himam Saheb
    This document summarizes the design of a go kart vehicle for a student karting championship. It describes the objectives of designing a safe and functional go kart based on a rigid frame. The design process considered safety, cost, availability of components, and engineering practices. A frame was designed from seamless steel tube and analyzed for stresses. Other components like the steering, brakes, wheels and engine were also designed and analyzed. Dimensions, material properties and fabrication details are provided to describe the fully engineered go kart design.

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    Design Report of A Go Kart Vehicle

    Uploaded by

    Shaik Himam Saheb
    911 views8 pages
    This document summarizes the design of a go kart vehicle for a student karting championship. It describes the objectives of designing a safe and functional go kart based on a rigid frame. The design process considered safety, cost, availability of components, and engineering practices. A frame was designed from seamless steel tube and analyzed for stresses. Other components like the steering, brakes, wheels and engine were also designed and analyzed. Dimensions, material properties and fabrication details are provided to describe the fully engineered go kart design.

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    Design Report of a Go Kart Vehicle

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    This document summarizes the design of a go kart vehicle for a student karting championship. It describes the objectives of designing a safe and functional go kart based on a rigid frame. The design process considered safety, cost, availability of components, and engineering practices. A frame was designed from seamless steel tube and analyzed for stresses. Other components like the steering, brakes, wheels and engine were also designed and analyzed. Dimensions, material properties and fabrication details are provided to describe the fully engineered go kart design.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    911 views8 pages

    Design Report of A Go Kart Vehicle

    Uploaded by

    Shaik Himam Saheb
    This document summarizes the design of a go kart vehicle for a student karting championship. It describes the objectives of designing a safe and functional go kart based on a rigid frame. The design process considered safety, cost, availability of components, and engineering practices. A frame was designed from seamless steel tube and analyzed for stresses. Other components like the steering, brakes, wheels and engine were also designed and analyzed. Dimensions, material properties and fabrication details are provided to describe the fully engineered go kart design.

    Copyright:

    © All Rights Reserved
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    of 8

    DESIGN REPORT OF A GO KART VEHICLE

    SHAIK HIMAM SAHEB1 GOVARDHANA REDDY 2 Md. HAMEED3


    123
    Assistant professor, Department of Mechanical Engineering
    Guru Nanak Institute of Technology, Hyderabad. himam.mech@gmail.com
    ABSTRACT
    This paper concentrates on explaining the design and engineering aspects of making a Go Kart for student karting
    championship 2015. This report explains objectives, assumptions and calculations made in designing a Go Kart.The teams
    primary objective is to design a safe and functional vehicle based on rigid and torsion free frame. The design is chosen such
    that the Kart is easy to fabricate in every possible aspect.

    INTRODUCTION
    We approached our design by considering all
    possible alternatives for a system and modeling them in
    CAD software SOLIDWORKS and subjected to analysis
    using ANSYS based on analysis result, the model was
    modified and retested and a final design was fixed. The
    design process of the vehicle is based on various
    engineering aspects depending upon
    Safety and Ergonomics
    Market Availability
    Cost of the Components
    Safe Engineering Practices
    With this we had view of our Kart. We set up some
    parameters of our work and team has been divided into
    core groups.
    Design
    Engine and Transmission
    Steering
    Brakes and wheels
    Business and Management

    Weld ability
    Availability
    Properties Of IS1161 Seamless Tube
    Properties

    Metric

    Ultimate tensile strength

    415Mpa

    Yield tensile strength

    310Mpa

    Poissons ratio

    0.3

    DIMENSIONAL SPECIFICATIONS
    Round tube of dimension = 25.4mm OD
    Thickness

    = 2mm

    LITERATURE REVIEW
    Being a new team we required a clear idea of
    basic requirements, parameters and design of Go Kart. We
    made a detailed study on Go Kart and visited Runway9,
    Hyderabad a Famous Go Karting Spot. We gained more
    knowledge during our field study and our basic doubts on
    dgn were cleared.

    DESIGN OF KART
    The following design methodology was used during
    design:
    Requirements
    Design calculations and Analysis
    Considerations
    Testing
    Acceptance

    JUSTIFICATION
    Round hollow tubes are light in weight

    MATERIAL SELECTION
    IS1161 is selected for the chassis because of the following
    reasons

    Machinability

    FABRICATION PROCESSES

    Lathe Work, Cutting, Drilling, Milling, Shaping ,


    Grinding, Polishing, Finishing, Welding

    Front Impact Analysis


    Using the gross weight of the vehicle is 160kg
    The impact Force was calculated based on G-load of 5

    Load applied: 2500N


    Maximum stress: 125.86Mpa
    Displacement: 6mm
    Factor of safety: 2.4
    Load applied: 5000 N
    Maximum stress induced: 171.8 Mpa
    Displacement: 1.9mm
    Factor of safety: 2.2

    Wheel Hub Analysis


    The following are the considerations took for the design of
    wheel hub for 25.4 mm shaft:
    Material: Mild Steel
    Braking torque: 975N-m
    Load: 1500N

    Side Impact Analysis

    Maximum stress : 182Mpa


    Yield strength: 221Mpa
    Factor of safety: 1.21

    Disc Hub Analysis


    The following are the considerations took for the design of
    wheel hub for 25.4 mm shaft:
    Material: Mild Steel
    Braking torque: 975N-m
    Load: 1500N
    Load applied: 3500N
    Maximum stress induced: 121.1Mpa
    Displacement: 1.14mm
    Factor of safety: 2.5

    Rear Impact Analysis

    Disc Hub Analysis (Cont..)

    Isometric View of the vehicle


    Maximum stress: 140Mpa
    Yield strength: 221Mpa
    Factor of safety: 1.57

    VEHICLE DRAWING AND DIMENSIONING

    Rear View of the vehicle

    Isometric view of the vehicle

    Side View of the vehicle

    Front View of the vehicle

    Top view of vehicle

    DIFFERENT VIEWS OF THE VEHICLE


    Top View of the vehicle

    DESIGN PARAMETERS

    CHASSIS

    Seamless tube

    WHEELBASE

    1066.8 mm

    turns with a small input and being more precise at the


    same time. We also attain a perspective turning radius of
    2.37meter.
    COMPONENTS

    OVERALL
    LENGTH OF
    VEHICLE

    TRACK WIDTH

    IS 1161

    1778 mm

    14 inch x 0.5 inch

    914.4 mm

    Front

    1066.8 mm

    Rear

    TYPE OF
    ENGINE

    3.5HP 127cc
    engine

    STEERING

    Mechanical
    linkage

    DIMENSIONS

    Tie Rod
    3 inch x 1.5 inch x 11mm
    King-Pin
    3.5 inch x 2.5 inch x 0.5 inch

    10*4.5*5

    Bracket
    front

    WHEELS AND
    TYRES

    11*7.1*5

    rear

    BRAKES

    Hydraulic disc
    brake

    Rear

    TRANSMISSIO
    N

    Centrifugal clutch

    MASS OF THE
    VEHICLE
    GROUND
    CLEARANCE

    1 inch x 2 inch x 10 mm
    Pit-man arm
    10 mm
    Bolt

    Steering shaft
    87.8kg

    approx.

    2 Inch

    from bottom most


    part

    STEERING SYSTEM
    Mechanical arrangement is planned to be used
    this type of steering system was selected because of its
    simple working mechanism and a steering ratio of 1:1 so
    to simple we have used mechanical type linkage.

    10 inch
    Steering wheel

    According to the Ackermann geometry the front


    tyres will rotate about the mean point as a result the entire
    force will act on the outer front tyre on a corner. Thus the
    cornering traction will be primarily governed by the outer
    tyre.
    We have chosen the mechanical linkage because it
    is cheap, light in weight and easy to manufacture.

    CONSIDERATIONS
    SELECTION

    Our steering geometry is having 99% Ackerman


    and also gives 60degree lock to lock turn of steering wheel
    which is very suitable for the race track as it allows quick

    20 inch x 1 inch

    FOR

    STEERING

    Amount of steering wheel travelling is


    decreased

    It is simple and cheap

    GEOMETRY

    VALUES

    Caster Angle

    12 degrees

    Camber Angle

    0 degrees

    King pin Inclination

    10 degrees

    Combined Angle

    10 degrees

    Toe-in

    5 mm

    Scrub Radius

    9 mm

    Minimum Turning Radius

    1.12 m

    Maximum Turning Radius

    2.59m

    CALCULATIONS
    Inner lock angle () = (total steering wheel rotation * 360)
    / steering ratio = 40 degrees
    Outer lock angle()= cot cot = w / l = 25.57degrees
    Ackerman angle calculation: Tan = (sin sin ) / (cos
    + cos 2) = 32.46 degrees
    Ackerman inside angle: = tan -1 (WB / (WB / tan
    TW)) = 13.36 degrees
    Ackerman percentage: %Ackerman = ((inside angle outside angle) / (Inside 100% Ackerman)) * 100% =
    99.97%
    Turning Radius(R max) Calculation

    No.

    diameter in
    mm

    mm

    Pulsar 150

    240

    Pulsar 220

    230

    Apache RTR 180

    200

    Reasons for selection for apache RTR 180 disc

    Thickness (6mm) is not too high

    Outer diameter is 200mm which is in


    accordance with our required design

    We have used floating type calliper in our design and


    finalised Apache RTR 180 calliper

    BRAKE FLUIDS
    We have decided to use DOT 3 Brake fluid
    Economical
    Easily available
    Compatible

    WEIGHT DISTRIBUTION
    Gross weight of the kart
    Front: Rear

    =
    =

    160kgs
    2:3

    Type

    Specification

    Rear disc

    OD 200 mm

    Master
    cylinder Dia.

    10 mm

    Caliper piston
    diameter

    25.4 mm

    Brake Pedal
    Lever ratio

    4:1

    Stopping
    distance

    2.237 m

    R min = length of wheel base / tan = 1.12 m


    R max 2= [R min + Wheel track width] 2 +Length of wheel
    base 2] = 2.59 m

    BRAKING SYSTEM
    The braking system has to provide enough
    braking force to completely lock the wheels at the end of a
    specified acceleration run, it also proved to be cost
    effective. The braking system was designed by determining
    parameters necessary to produce a given deceleration, and
    comparing to the deceleration that a known braking
    system would produce.
    Considerations for braking system selection:
    Discs, calipers and master cylinders which were
    used for considering suitable vehicle after market survey

    CALCULATIONS
    Sr.

    Disc

    Outer

    Thickness in

    1.Gross weight of the vehicle

    v2 u2 = 2*a*ds (v=0,u=12.5m/s)

    W = weight of the vehicle (with load conditions) in kgs


    * 9.81= 160*9.81=1569.6N

    Stopping Distance =2.2370meters

    2. Brake line pressure :


    p = force on the brakes / area of master cylinders
    (as pedal ratio is 4:1)
    ( Assume the normal force applied on the pedal: 350n)
    = pedal ratio *force on the pedal / area of master cylinder

    ENGINE AND TRANSMISSION


    The engine in deployed in our Kart is BRIGGS
    and STRATTON 3.5HP 127 CC it has 14kg weight with
    single cylinder.

    ENGINE SPECIFICATIONS

    = 4*350/(/4)*(0.01)2
    = 17.8343Mpa

    Configuration

    Value

    Engine Technology

    single cylinder , 4stroke,air cooled ,


    OHV(Over Head Valve)

    Maximum Power

    3.5 HP@3600 R.P.M

    Gross Torque

    7.5 N-M@2600 R.P.M

    Bore*Stroke

    62mm*42mm

    Displacement

    127cc

    Dry Weight

    14 Kg

    Fuel Capacity

    1.8L

    Length

    261mm

    Width

    347mm

    Height

    326mm

    3.Clamping force (CF):


    Cf= brake line pressure *(area of caliper piston*2)
    = 17.8343*( ( / 4 ) * (25.4 * 10-3 ) 2 * 2 )
    = 18064.6825N
    4. rotating force:
    RF = CF* number of caliper pistons * coefficient friction
    of brake pads
    =18064.4334*0.3*2
    =10838.6825N
    5. braking torque (tn) = rotating force* effective disc
    radius
    =10838.6825*0.09
    =975.48 N-m

    Assuming transmission efficiency =

    80%

    (torque available at the two tires of the rear shaft)

    Gross weight of the Kart

    160kgs

    6. braking force=(braking torque /tire radius)*0.8

    number of teeth on CVT output

    =6982.6677*0.8

    number of teeth on rear shaft sprocket=36

    =5586.0820N

    Ratio

    =54

    =0.66:1

    7.deceralation:
    f=-ma(-ve sign indicates force in opposite
    direction)
    SPEED
    (RPM)

    CVT RATIO

    SPROCKET
    RATIO

    FINAL
    RATIO

    =-34.913m/s

    1850

    16

    0.66

    10.56

    8. stopping distance:

    2750

    10

    0.66

    6.6

    a=-B.f/m=5586.0820/160

    3600

    6.4

    0.66

    4.224

    CALCULATIONS
    Speed
    = (circumference of the wheel *
    rear shaft rpm) / (60*1000) m/s
    =
    (60*1000)

    *11*25.4*852.27

    )/

    = 12.468 m/s
    = 44.86 km/hr.
    Drive torque

    = engine torque * reduction *


    efficiency
    =7.5*16*0.66*0.8 = 63.36 Nm

    Drive force

    = drive torque/radius of wheel


    = 63.36*1000/5.5*25.4 =

    453.54 N
    Acceleration

    SPECIFICATIONS

    VALUES

    KNEE ANGLE

    150 DEGREES

    ELBOW ANGLE

    95 DEGREES

    = Drive Force/mass
    = 453.54/160= 2.83 /s2

    ELECTRICALS
    BODY WORKS
    External appearance of the vehicle depends upon
    bodyworks. It is an important part of the vehicle design. It
    also dominates sale and marketing of the vehicle.
    We have selected fiber on the basis of market survey
    because of its

    light weight

    good electrical insulator

    SAFETY AND ERGONOMICS


    Safety is the most important concern for our Gokart. Bumper is provided for safety. In addition fire
    extinguishers and kill switches will also be used in case of
    emergency. Ergonomics are designed perfectly for the
    comfort of the driver.

    12V DC Battery will be used to power all the


    electrical components.
    CONCLUSION:
    The design and construction for GO-KART DESIGN
    CHALLENGE 2015 has become more challenging due to
    the increased participation. Our team is participating for
    the first time in this event so a detailed study of various
    automotive systems is taken as our approach. Thus this
    report provides a clear insight in design and analysis of
    our vehicle
    The making of this report has helped us in
    learning of various software. We want to give a vote of
    Thank you in this regard as GKDC competition has given
    as this opportunity to learn many things which will also
    help us in leading a bright future.

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    19. Automotive Mechanics-William H Crouse

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