design and analysis of a go-kart chassis

e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science

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DESIGN AND ANALYSIS OF A GO-KART CHASSIS BYCOMPARING

DIFFERENT MATERIALS

K. Nagendra*1, G. Venkata Ramana Reddy*2, Pakide Vijay*3,

K. Anil Yadav*4, G. Navaneeth Reddy*5 *1Assistant Professor, Mechanical Engineering, Ace Engineering College, Ghatkesar,

Hyderabad, Telangana, India.

*2,3,4,5Students, ACE Engineering College, Mechanical Engineering, ACE Engineering College,

Ghatkesar, Hyderabad, Telangana, India.

ABSTRACT

A Go-Kart is a small four wheeled vehicles without suspension or differential. It is a light powered vehicle which

is generally used for racing. This paper is aimed to model and perform the static analysis of the go-kart chassis

which is of constructed with circular beams. Modelling and analysis are performed in CATIA and ANSYS

respectively. The go-kart chassis is different from ordinary car chassis. The chassis is designed in such a way

that it requires less materials and ability to withstand loads applied on it. Strength and light weight are the

basic consideration for choosing the chassis material. Structural steel, AISI 1010 and AISI 4340 is the suitable

material to be used for the go-kart chassis which is a medium carbon steel having high tensile strength, high

machinability and offers good balance of toughness and ductility. In this project we analyzed the materials AISI

4340, AISI 1010 and Structural steel. Then we find the strength, von-misses stress, and Total deformation of the

chassis.

Keywords: Analysis, Suspension, Modeling, CATIA, Static Analysis, Go-kart.

I. INTRODUCTION

The Go-Kart is a vehicle which is simple, light weight and compact and easy to operate. The go-kart is specially

designed for racing and has very low ground clearance when compared to other vehicles. The common parts of

go-kart are engine, wheels, steering, tires, axle, and chassis. No suspension can be mounted to go-kart due to its

low ground clearance and the driving is trembling. Both two stroke and four stroke engines are used for go-

kart. Electric motor engines are also used for go-kart and are called as Eco kart. The go-karting is a variant open

wheel motor sport with small, open, four wheeled vehicles. The chassis is independent of suspension to

experience thrill. Because of its simplicity and economical, go-kart is the most interested thing for most of the

users. The tracks go-kart is like F1 racing track. A go-kart is powered by 125cc engine in most of the countries.

In some countries, go-karts can be licensed for use on public roads. Typically, there are some restrictions, e.g.,

in the European nations go-kart on the road should needs of different factors like head light (high/low beam),

taillights, a horn, indicators and a maximum of 20 HP. It is well known that Kart racing is usually a low-cost and

relatively safe way to introduce drivers to motor racing. The go kart chassis is like a skeleton frame which is

made up with hollow pipes and different materials which having different cross sections. As the suspension is

not present for go kart it should be designed in way with high torsion rigidity because it is having a high

relative degree of flexibility. The chassis is designed in such a way that it should ride safe and the load that

applies does not change the structural strength of the chassis. The chassis is the backbone of the kart as it must

be flexible so that it must be equal enough to the suspension. The chassis could carry and support the power

train, power unit, running system, etc. the go kart chassis is classified into different types such as open, caged,

straight, and offset.

➢ Open karts do not have chassis.

➢ Caged kart chassis surrounds the driver and have a roll cage which is mostly used in dirt tracks.

➢ Straight chassis is the commonly used and driver sits at the center. This kind is used in sprint racing.

PA RTS OF A GO – KA RT:

In a Go-Kart, there are mainly six parts. They are:

1. Chassis





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2. Engine

3. Steering

4. Transmission

5. Tyres

6. Brake

7. Electric Starter

CHASSIS:

Chassis is a frame made of hollow pipes and different materials are used of various cross-section. It should have

high torsional rigidity and high degree of flexibility because the vehicle should be stable and should have high

strength. High degree of flexibility will give enough strength to withhold or grub the different load applied on

the vehicle as well as its different accessories. While designing the chassis different criteria and factors that

should be considered are its safe ride, structural strength due to applied load and ergonomics. Selection of

frame material While designing any chassis, strength and light weight are the basic consideration. So, material

used in chassis is one of its important criteria.

The characteristic of chassis is:

• high Strength

• Durability

• Easy of Control

• Economy of Operation

• Stability

• Simplicity of Lubrication

• Fast Pickup and Safety

INTRODUCTION TO CATIA:

CATIA (the full form of CATIA is Computer-Aided Three-Dimensional Interactive Application) is the most

widely used Design tool from Dassault Systems. It is a complete suite that incorporates CAD, CAM, and CAE.

CATIA delivers 3D design, CAE, CAM, and Product Lifecycle Management (PLM) solutions. The software is

commonly used in manufacturing industries and Original Equipment Manufacturers (OEMs) to increase the

process of designing, analyzing, and management of new products. CATIA is a solid model tool that combines

3D parametric features with 2D tools and even addresses every design-to-manufacturing process. It also

provides generating section, auxiliary, isometric, detailed 2D drawing, or orthographic. Thus, this software

serves the best for creative designers, mechanical engineers, system architects, and manufacturing industries.

The development of Software depends on the requirement of the industries. No doubt, all developers of CAD

software try to bring up something unique and better. Since 1980, CATIA has been constantly developing its

versions to satisfy the need for design. CATIA V3 and V4, CATIA V5, CATIA V6.

INTRODUCTION TO ANSYS:

Ansys has been founded in 1970 and incorporated in 1994. Ansys predominantly offers engineering simulation

software and ancillary services. The solutions provided by the company are used in a wide range of industries

including aerospace, defence, automotive, biomedical, and other industrial sectors. Ansys has been recognized

as one of the world's most innovative companies by prestigious publications such as Bloomberg Businessweek

and FORTUNE magazine for its engineering simulation software. Leveraging the power of today's Desktop,

Ansys provides a common platform for product development, from design concept to final-stage testing and

validation.

The company's product portfolio consists of simulation platform offerings that are used in diverse multi-

physics fields like heat transfer, fluid mechanics, statics, solid mechanics, etc. However, Ansys is best known for

finite element analysis (FEA). Before discussing Ansys software further, let us understand very briefly what

FEA is and why it has gained prominence in recent times. There are three broad methods to solve complex

engineering problems: analytical methods, experimental methods, and numerical methods. While analytical

methods provide accurate solutions, they are limited to minimal geometries. Experimental methods can give





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accurate results, but they are costly, and in most cases not feasible financially. Finite element analysis (FEA), a

numerical method to solve engineering problems, is a very versatile and comprehensive numerical technique

that provides reliable engineering solutions. The most salient feature of FEA is the discretization of a given

domain into a set of simple sub-domains called finite elements.

II. METHODOLOGY 3d model of chassis frame is generated by using CATIA software.

3d model of chassis frame is converted into Parasolid file.

The Parasolid file is imported to ANSYS software to perform analysis on chassis assembly.

Transient Static structural analysis performed on the chassis frame for 60 Kph front impact for period of

70ms. The deflections and stresses are plotted and documented.

Transient Static structural analysis performed on the chassis frame for 50 Kph side impact for period of 70

ms. The deflections and stresses are plotted and documented.

Transient Static structural analysis performed on the chassis frame for 30 Kph rear impact for period of

70 ms. The deflections and stresses are plotted and documented.

III. LITREATURE REVIEW

1) Mr. Kartik Kelkar1, Mr. Siddhant Gawai2, Mr. Tushar Suryawanshi3, Mr. Shaikh Ubaid4, and Mr.

Rajratna Kharat5: This paper aims to do modeling the static analysis of go-kart chassis consisting of circular

beams. Modeling and analysis are performed using 3-D modeling software i.e., CATIA & static analysis in ANSYS

14.5. The maximum deflection is obtained by analysis. The go-kart chassis are different from the chassis of

ordinary cars on the road. The material used and structural formation of chassis. The loads are applied to

determine the deflection of chassis.

2) Mr. Virendra.S. Pattanshetti: This paper deals with the Design and Analysis of Roll Cage for the Go Kart. In

a Go Kart Student Car, the roll cage is one of the main components. It forms the structure or the main frame of

the vehicle on which other parts like Engine, Steering, and Transmission are mounted. We have made the 3D

model of Go Kart and Roll Cage in Catia-V5. Roll Cage comes under the sprung mass of the Vehicle. There are a

lot of forces acting on vehicle in the running condition. These forces are responsible for causing crack initiation

and deformation in the vehicle. Deformation results in Stress Generation in the Roll Cage. Hence it is important

to find out these areas of maximum Stresses. In this paper an attempt is made to find out these areas by

carrying out FEA of the Roll Cage. We have carried out Crash Analysis (Front and Side Impact), Torsion

Analysis. All these Analysis have been carried out in Hyper Works 11.0. The design procedure follows all the

rules laid down by NKRC Rule Book for Go Kart Type Cars.

3) Sannake Aniket S., Shaikh Sameer R., Khandare Shubham A., Prof. S.A. Nehatrao: A Go-Kart is a small

four wheeled vehicles without suspension or differential. It is a light powered vehicle which is generally used

for racing. This paper is aimed to model and perform the dynamic analysis of the go-kart chassis which is of

constructed with circular beams. Modelling and analysis are performed in CREO PARAMETRIC and ANSYS

respectively. The go-kart chassis is different from ordinary car chassis. The chassis is designed in such a way

that it requires less materials and ability to withstand loads applied on it. Strength and light weight are the

basic consideration for choosing the chassis material. AISI 1018 is the suitable material to be used for the go-

kart chassis which is a medium carbon steel having high tensile strength, high machinability and offers good

balance of toughness and ductility.

4) Kiral Lal, Abhishek O S: A Go-kart is a small four wheeled vehicle. Go-kart, by definition, has no suspension

and no differential. They are usually raced on scaled down tracks but are sometimes driven as entertainment or

as a hobby by non-professionals. 'Carting is commonly perceived as the steppingstone to the higher and more

expensive ranks of motor sports. Kart racing is generally accepted as the most economic form of motor sport

available. As a free-time activity, it can be performed by almost anybody and permitting licensed racing for

anyone from the age of 8 onwards. Kart racing is usually used as a low-cost and relatively safe way to introduce

drivers to motor racing. Many people associate it with young drivers, but adults are also very active in karting.

Karting is considered as the first step in any serious racer's career. It can prepare the driver for highs-speed

wheel-to-wheel racing by helping develop guide reflexes, Precision car control and decision-making skills. In





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addition, it brings an awareness of the various parameters that can be altered to try to improve the

competitiveness of the kart that also exist in other forms of motor racing.

5) Koustubh Hajare, Yuvraj Shet, and Ankush Khot: This paper aims to the design analysis of a go kart

chassis. The main intention is to do modelling and static analysis of go-kart chassis. The maximum deflection is

obtained by analysis. The go-kart chassis are different from chassis of ordinary cars on the road. The paper

highlights the material used and structural formation of chassis. The strength of material, rigidity of structure

and energy absorption characteristics of chassis is discussed. The modelling and analysis are performed using

3-D software such as SOLIDWORKS, ANSYS and HYPERMESH. The loads are applied to determine the deflection

of chassis.

6) Harshal D. Patil, Saurabh S. Bhange, and Ashish S. Deshmukh: There are many motor sports in the

world. Bikes, Cars, Formula one is examples of them. But there are also motor sports which do not need

professional drivers and need no great speed. The vehicles used are also very cheap. Such a motor sport is Go-

Karting. Go-kart is a simple four-wheeled, small engine, single seated racing car used mainly in United States.

This paper explains the designing and fabricating a sound kart having high fuel economy and maximum driver

comfort and compactness without compromising on kart performance. This research also includes designing

kart for the performance and serviceability. Compliance with the rulebook of NKRC 2015 is compulsory and

governs a significant portion of the objectives. This report describes in detail 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. Analyses are conducted on all major

components to optimize strength and rigidity, improve vehicle performance, and to reduce complexity and

manufacturing cost. The design has been modelled in CATIA V5R21; the analysis was done in ANSYS 14.5 and

simulation in ADAMS14.

7) Abhijit Padhi, Ansuman Joshi, Hitesh N: had proposed a project which aims to increase the factor of safety

of the Go-Kart chassis which is designed keeping in mind the rules imposed by Go – Kart Design Challenge

2015. Theoretical calculations are carried out which have been realized through several analyses. These result,

coupled with appropriate research has been used to create a new chassis that possesses improved performance

and safety. During front impact analysis, the chassis should meet the required factor of safety. To enhance

factor of safety the computer aided design model was altered marginally such that it meets the safety

requirements. An innovative method of design optimization has been discussed, without significant increase in

the overall kerb weight of the chassis.

IV. MODELING AND ANALYSIS

The amount of carbon in steel is important to determine the strength, hardness, and machining characteristics.

Material selection of the frame plays an important role in providing desired strength, endurance, safety, and

reliability of the vehicle. The material used for chassis are various grades of steel or aluminum alloys. The main

component of steel is carbon which increases the hardness of material of chassis. Aluminum alloy is expensive

than steel so mainly steel is used to constructs the chassis.

3D model of the chassis was developed in CATIA. The model was then converted into a Parasolid to import into

ANSYS. A Finite Element model was developed with solid elements. The elements that are used for idealizing

the chassis model are described below. A detailed Finite Element model was built with shell elements to

idealize all the components of chassis. A total number of 11137 elements were created using shell element type.

MATERIALS AND THEIR PROPERTIES:

S.No Parameter STEEL AISI- 4340 AISI-1010

1 Young’s

Modulus(N/mm2) 203000 203000

200000

2 Poisson's ratio 0.29 0.3 0.33

3 Ultimate Tensile 460 740 365





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Strength (Mpa)

4 Yield Strength,

(Mpa) 250 470 305

ANALYSIS:

Figure 1: 3D view of chassis.

Frontal impact test:

Front impact test is which people usually think about a crash test. In this test, the material made to be fixed at

one end while other is allowed to have an impact force. The front impact can be tested by using ANSYS

software, where we can test the front impact force up to which it can withstand and to find the stress produced

on the front side of the chassis. Now keeping the rear part fixed; the calculated force is applied to the Front part

of the frame.

The velocity of 60 Kph (16680 mm/sec) for frontal impact was applied over the period of 70 ms on the

chassis as shown in the below figure.

Figure 2: Velocity boundary condition for chassis frontal impact

Side Impact Test:

Side impact is usually occurring when another vehicle hits on the side of the vehicle. So, the impact on this side

is found virtually using the analysis software, itself. The side impact is tested by using ANSYS software, where

we can test the side impact force up to which it can withstand and to find the stress produced on the side of the

chassis. Now keeping one side of the frame fixed, the calculated force is applied on the other side of the frame

and the results are as follows.





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The velocity of 50 Kph for side impact was applied over the time- period of 70ms on the chassis as shown in

the below figures

Figure 3: Velocity boundary condition for chassis side impact

Rear Impact Test:

The rear impact force is created by the collision in the traffic accident wherein a vehicle crashes at its rear side.

It causes damages at the end causing deformation at the back side of the vehicle. The rear impact is tested by

using ANSYS software, where we can test the rear impact force up to which it can withstand and to find the

stress produced on the rear side of the chassis. Now keeping the front side of the frame fixed the calculated

force is applied on the rear side of the frame and the results

are as follows

The velocity of 30 Kph for rear impact was applied over the time-period of 70 ms on the chassis as shown in

the below figures.

Figure 4: Velocity boundary condition for chassis rear impact





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V. RESULTS AND DISCUSSION

Figure 5: Total deformation of the chassis frame frontal impact

Figure 6: Von-mise’s stress for the frontal impact

Figure 7: Total deformation of the chassis for side impact





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Figure 8: Zoom view of Von-Mises’s stress plot of chassis for side impact

Figure 9: Total deformation of the chassis for rear impact

Figure 10: Von-Mises’s stress plot of chassis for chassis rear impact

For frontal impact

properties AISI 4340 AISI 1010 STEEL

Total

deformation 494.0mm 639.0mm 66.3mm

Equivalent stress 1577Mpa 7303Mpa 698.2Mpa





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For side impact


Total

deformation 639mm 508mm 65.838mm

Equivalent

stress 730Mpa 3259Mpa 23.48Mpa

For rear impact


Total

deformation 166.2MM 532.06mm 3.17mm

Equivalent

stress 676.4Mpa 1245Mpa 28.79Mpa

VI. CONCLUSION

In this project, impacts and collisions involving a go-kart frame model were simulated and analyzed using

ANSYS software. The given model was tested under different collision conditions and the resultant deformation

and stresses were determined with respect to a time of 70 Mille sec for ramp loading using ANSYS software.

Static Structural analysis was done on chassis frame in different directions using ANSYS software. From the

above analysis results it is concluded that the go-kart chassis frame is safe for impact loading.

After performing the Front impact, side impact and rear impact analyses and making the necessary changes, the

following design was finalized. • It is cleared from the present investigation. STEEL ALLOY is a more efficient

material as it gives a sale result for the different loading criterion.

VII. REFERENCES

[1] Mr. Kartik Kelkar1, Mr. Siddhant Gawai2, Mr. Tushar Suryawanshi3, Mr. Shaikh Ubaid4, and Mr.

Rajratna Kharat5, “STATIC ANALYSIS OF GO-KART CHASSIS”, International Journal of Research in

Advent Technology, Issue: 09th April 2017.

[2] Mr. Virendra’s. Pattanshetti “DESIGN AND ANALYSIS OF GO KART CHASSIS” International Journal of

Mechanical and Industrial Technology, Vol. 4, Issue 1, Month: April 2016 - September 2016.

[3] Sannake Aniket S., Shaikh Sameer R., Khandare Shubham A., Prof. S.A. Nehatrao, “DESIGN AND

ANALYSIS OF GO-KART CHASSIS”, International Journal of Advance Research and Innovative Ideas in

Education, Vol-3, Issue-2 2017.

[4] Kiral Lal, Abhishek O S, “DESIGN, ANALYSIS AND FABRICATION OF GO-KART”, International Journal of

Scientific & Engineering Research, Volume 7, Issue, April-2016.

[5] Koustubh Hajare, Yuvraj Shet, and Ankush Khot, “A Review Paper on Design and Analysis of a Go-Kart

Chassis”, International Journal of Engineering Technology, Management and Applied Sciences,

February 2016, Volume 4, Issue 2.

[6] Harshal D. Patil, Saurabh S. Bhange, and Ashish S. Deshmukh, “DESIGN AND ANALYSIS OF GO-KART

USING FINITE ELEMENT METHOD” International Journal of Innovative and Emerging Research in

Engineering Volume 3, Special Issue 1, ICSTSD 2016.

[7] Abhijit Padhi, Ansuman Joshi, Hitesh N “Increase Factor of Safety of Go-Kart Chassis during Front

Impact Analysis”, IJIRST –International Journal for Innovative Research in Science & Technology,

Volume 3, Issue: 04 September 2016.

[8] Gautam Yadav, Dhananjay Aakash Ahlawat, Gaurav Gilia, “GO KART DESIGNING AND ANALYSIS”,

JIAATS-JCME, Vol-15, ISSN-3347-4482, November 2014.

[9] N. R. Patil, Ravichandran R. Kulkarni, Bhushan R. Mane, Suhail H. Malvi, “STATIC ANALYSIS OF GO-

KART CHASSIS FRAME BY ANALYTICAL AND SOLIDWORKS SIMULATION”, IJSET, ISSN: 2277-1581,

Volume No.3, Issue No.5, pp: 661-663, 1 May 2014.

[10] Mr. Girish Mekelle, “STATIC ANALYSIS OF A GO-KART CHASSIS”, IJMIT, Vol-3, Issue 2, pp: (73-78), ISSN

2348-7593, October 2015 - March 2016.

design and analysis of a go-kart chassis

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