Design and FEA of Go Kart Chassis

Design and FEA of Go Kart Chassis

Bhosale Nagesh Baburao Mechanical Engineering Department Jaihind College of Engineering Kuran Pune, India

Darandale Gaurav Narayan Mechanical Engineering Department Jaihind College of Engineering Kuran Pune, India

Abstract- Chassis is basis foundation of any Automobile locomotive. Go-Kart is primary form of racing car where engineers can make use of theoretical knowledge with practical existence. There are various kinds of chassis out of which Tubular frame chassis are suitable for small vehicle. Design of chassis is on the basis of rigidity, strength and safety of driver by considering car that is durable as well as reliable whose material easily available in India. The kart has been designed using sound design principles .Go-kart is small four wheeler vehicle without suspension light powered vehicle used for racing. Basically CREO, CATIA, AUTO-CAD software are used for designing of Chassis whereas ANSYS- BENCHWORK software is used for Analysis of Chassis. Chassis is made up of joining various small links by using welding with limited number of joints so to avoid increase of weight and make the chassis strong enough to withstand high load.

Keyword- Sound; Design Principles; Go-Kart

1. INTRODUCTION

   Chassis word derived from French which is divided into two parts, one as running gear and another one is power plant. Running gear consist frame, steering system, brakes, wheels and the tyres. The power plant includes the engine assembly and power transmission assembly. Important things in chassis are it must be rigid, having high strength, good impact resistance, better rigidity, good compressive and tensile properties within structure etc. along with that weight is effective parameter in case the chassis is for racing purpose. Go-Kart is good example of that where engineer face the above problem. Go-kart frame should be enough strong to with stand shocks, twists, and vibrations and all other stress. This Paper deal with design of Go-Kart Chassis and various loading test like front impact test, side impact test, rare impact test, all these tests have done on ANSYS software by application of 1Ton load. The Chassis is designed to withstand 1 Ton load by using limited welded joint so that Chassis dont look like a bulky and make it lighter.

2. OBJECTIVE OF PAPER

   1. To get knowledge of Go-Kart Chassis Design for beginner in stepwise manner so to avoid unnecessary thing and focuses on competition.

   2. Focusing area of analyzing Software to get desirable result.

   3. To make use of welding alternative of hydraulic press.

      Deshmukh Mahesh Bhaskar Mechanical Engineering Department Jaihind College of Engineering Kuran Pune, India

      Fadale Jignesh Laxman Mechanical Engineering Department Jaihind College of Engineering Kuran Pune, India

   4. Use of welding Principle effectively without increasing weight of chassis and make it simple.

3. SCOPE OF PROJECT

   1. Go- kart is gaining wide popularity as it is suitable for most of people to make their own playing car as well as working car by using their knowledge and competition with other in racing.

   2. Making advance engineering Knowledge to use at chassis for making it better and light weight.

   3. Using variety of material to make better chassis for various applications and mostly for racing purpose.

   4. Practice Engineering knowledge with budgeting for making Cost effective chassis.

4. METHODOLOGY

   For compilation of project following steps have to be performed:

   1. Selection of Material.

   2. Material Purchasing.

   3. Designing.

   4. Analysis.

   5. Manufacturing

   6. Testing.

5. SELECTION OF MATERIAL

   As project is focusing on manufacturing of Go-Kart chassis for racing purpose so project developed team have followed the material list provided by the Racing organizer and National Event Rule these are as follows:

   Properties of Material	AISI 1018	AISI 1022	AISI 4130
   Modulus of elasticity (GPa)	205	200	210
   Carbon content %	0.15-20	0.20-23	0.28-33
   Yield strength (MPa)	370	375	435
   Ultimate strength (MPa)	440	400	560
   Density (Kg/m3)	7.87×103	7.70×103	7.85×103

   Table I. Selection of Material

   From Table Material AISI 1018 having desirable properties for chassis we can clearly see.

   We can also use the Hybrid or composite material but team have to justify their material selection this stage is better for expert person but for beginner should avoid it for short time period availability and taken into consideration in case of excessive time.

   Cross-section of small link for the chassis formation is given in Rulebook. We can follow that procedure.

6. MATERIAL PURCHASING

   This is next step followed by Material selection, for this student have sufficient knowledge of market. Student can fulfill this requirement by surveying market, use of social media contact, use nonsocial contact, getting help from expert etc.

   In Front side analysis of chassis it is clearly seen that after impact major deformation take place at side of bumper and reduced its effect toward chassis.

   1. Left Hand Side Analysis

      Note: This is vast Process student or beginner must start this process at the beginning of project.

7. DESIGNING

   Before going to do design our team has done theoretical calculation by using engineering knowledge to find out SFD, BMD. After making of rough calculation the team moves towards to software designing.

   There are various softwares are available for designing as well as analysis our team have used different software for designing and analysis.

   Procedure followed by team is:

   • Drawing rough diagram on drawing sheet for finding of required dimension.

   • Drawing actual model on CATIA (CREO/ProE) as this gives 3D and 2D view for better understanding.

   • Assembled various parts of chassis because of welded joint.

   • Converting 3D model file into .stp format for analysis purpose.

     Fig.2.Left Hand Side Impact Analysis

     In this analysis impact effect is limited up to the left hand side bumper only and several damages happen at middle shaft.

     Fig.3.Right Hand Side Impact Analysis

   1. Right Hand Side Analysis

8. ANALYSIS

   Our team has done analysis in ANYSIS which gives following Result for load of 1 Ton:

   A .Front Side Analysis

   Fig.1.Front Side Impact Analysis

   Fig.3.Right Hand Side Impact Analysis

   We can see same condition happen as in result of Left Hand Side Impact.

   Fig.4.Rare Side Impact Analysis

   1. Rare Side Analysis

   Fig.4.Rare Hand Side Impact Analysis

   In the rare side Analysis impact effect if more on end of bumper and less on chassis this means that our chassis is safe in rare side.

   As analysis gives result which shows chassis is safe from all side of impact load of 1 Ton.

   Table II. Analysis Result

   Analysis Type	Force Applied	Number Nodes	Type of Solution	Min Results	Max Results
   Static Structural	10000 N	668675	Total Deformation	0 mm	7.6406 mm
   Static Structural	10000 N	668675	Equivalent Stress	0 MPa	59.32 MPa
   Static Structural	10000 N	668675	Equivalent Strain	0 mm/mm	0.0038857 mm/mm
   Static Structural	10000 N	668675	Life	702.79 cycles	1e6 Cycles
   Static Structural	10000 N	668675	Factor of Safety	0.56118	15

9. MANUFACTURING

   Manufacturing is done by Oxy-Acetylene welding on outer side frame as per heavy part location and Arc welding is used for inner side.

10. TESTING

    Testing is done by applying load up to design criteria and tests the chassis. We have find chassis is safe for that load.

11. CONCLUSION

So we have manufactured Go-kart Chassis with a very simple manner and simple manufacturing technique i.e. welding only. This saves our time and makes our chassis simple which can withstand a load of 1 ton. Chassis have more number of weld which affect its strength can be overcome by use of hydraulic press to make continuous shape and increase its strength but it result into cost increment.

REFERENCES

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10. Prashant Tiwari, Go-Kart Championship-2013, RIT INDORE.

11. Go-Kart Rulebook 2016-2017.