final design report1
DESCRIPTION
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PAPER NUMBER:3
DESIGN REPORT
AUTHOUR: PAVAN KUMAR
BHARAT INSTITUTE OF ENGINEERING AND TECHNOLOGY- DESIGN REPORT
ABSTRACT
MECHMANIACS needed to make a design in Go-kart racing held by Elite Techno Groups 2014. A Team was formed with a goal of reducing the cost of manufacturing of Go-kart and increase factor of safety, including good ergonomics for driver safety which is the main aim. After careful consideration of possible causes and solutions of 5 factors design was completed .The factors are Chassis (rigidity, strength, material, composition, size of material, type), Brakes (type, disc diameter, amount of heat Dissipation , Clutches (type, availability), Wheels (size, composition), Steering (type of mechanism, location).The aim of the competition is to make students to work as a team to DESIGN, ANALYSE, MANUFACTURE, PROMOTE, COMPETE within the rules provided. On hand practice and exposure to Future automotive professional’s
INTRODUCTION
MECHMANIAS Team is one of the competitor in go-kart Student racing Contest for the first time. This the first time for our team MECHMANIAS to participate in any national wide racing event .we took this as a challenge and worked hard in designing, in searching for sponsers, In fabricating ,in testing. This competition gave us a chance to learn many things and to prove ourselves. To achieve the five factors mentioned above there are many ways available in market. The design can be done through various Software:, Our choice
among them is Solid Works and CATIA, other teams may use other Software like Pro-E, ANSYS, Auto Cad etc.,. Since they are software used for much complex components but our project does not contain such complex components as we want to make our Go-kart very simple so we didn’t prefer those. Using Solid Works we can perform both designing and analysis on a single platform which helps in time management and we want to use adjustable steering rod which helps the driver to move freely and come out of the vehicle within 4 seconds in fully seated position. Thus we can produce go-kart which provides more space to driver and make him feel safe.
.Based on these aims we made several design approaches, analysis approaches. We got divided the work in to three tasks one is to give ideas and conceptual approach towards building .second is to deciding the way of approaches to implement those concept and testing ,third is to implement those approaches in designing and manufacturing .In this design report we are going to present detailed description of our design approach ,analysis approach ,method of selection of parts, pictures of our design, technical details of analysis and uniqueness of our approaches compared to other teams.. DESIGN PHILOSOPHY:
TO produce a design which would be prototype for manufacturing of most reliable ,simple, cost effective, most importantly safe and to be different
compared to remaining teams and keeping In my the rules we followed the following way of approach
1) Conceptual Approach:Many teams directly start there designing and start their planning while deigning which is much complicated and may result in many errors, time consuming. we didn’t want that to happen for us so we initially made numerous rough sketches by observing many go-kart available, by discussing about the them, we made tremendous research regarding go-karts and finally by keeping in mind all the information we collected ,based on rules given in rulebook each individual of our team made a rough discuss about the problems in each design finally left out with 3 to four rough sketches
2) Selection of software:In order to deign our go-kart it is necessary for our team to select a Software among many design software available. As we didn’t designed any part till now this made us to learn any of the software which is simple and easy to understand by attending the workshop we learned software like Solidworks, Catia and Autocad in less time and started designing our chassis, brakes, steering
3) analysis:After making three designs we have to those the best among them in order to do so we have to check the ability of vehicle to carry and withstand the load ,load analysis, structural analysis, mainly factor of safety is to be checked for each design as safety is one of our most important element. we did our analysis in Solidworks and finally decided a design by comparing its deformation .factor of safety, and stress analysis as given in end of the report
4) GOAL AND CONSTRAINT SETTING:After analysis we concluded our design by the constraints we indentified like rules, maximum length, maximum width as mentioned in b.1.2 rule; mass of go-kart, condtion between wheel base and track widths of front and rear as mentioned in B.1.1 AND B.1.13 ,TOLERANCES which can be used and center of gravity location, as well as specific constraintsfor each subsystem of the vehicle. DESIGN OBJECTIVES :
Based on our research on various Go-karts, ANALYSIS AND VARIOUS OTHER CONSIDERATION THE MAIN OBJECTIVES AND CONSIDERATIONS HAVE BEEN SET THEY ARE
SIMPLE AND EASY TO MANUFACTURE Reliable and cost effective Weight reduction safety
CHASSIS
We designed our chassis of 70mm long and 44 inches wide based on few considerations like Height, Length, width, weight, strength, toughness and also by few objectives. THE consideration we made chassis design and manufacturing are as follows
DRIVER ERGONOMICS:It is the most important consideration in chassis design since driver is situated in middle of the go-kart and all the parts are located around him or her. centre of gravity comes to picture hence it is kept as low as possible. Initially we assume the driver ergonomics as ideal values later finalized by doing iterations of 1degree each .By trying different ranges and seating positions of 4 different drivers we got the values by averaging them keeping in mind that it must be selected such a way that there is clear view to driver and it is suitable to the design intent should be to accommodate drivers ofall sizes from the 95th percentile male to the 5th percentile female. The largest driver will be ableto meet the roll cage minimum clearances, and fit into a comfortable driving position, while wearingthe entire required driver’s equipment. The smallest driver must be able to comfortably reach all of the vehicle’s controls. The driver seat we are using is made up with GLASSFIBER seat with good strength. for safety we are also using fire extinguisher ABC type, 1kg dry co2.kill switch of 12volt DC,3 point harness with push lock release
WEIGHT REDUCTION:Our goal is to reduce the weight as much as possible without loosing it capacity to carry the weight of driver and remaining parts. We didn’t selected remaining two deigns since it weights more than our final design the weight of the design is achieved is 52.17 pounds
FRAME CAPACITY:Frame capacity include rigidity of frame, its load bearing capacity, its deformation level to applied force in any direction .in order to achieved good rigidity we initially analysed the first to basic designs in SOLIDWORKS using FEA and made few changes in design to achieve highest possible rigidity .in order to achieve highest rigidity, selection of material plays very important role by doing market survey we selected few materials individually applied those materials and analysing them we selected AISI4130 NORMALISED STEEL Yield Strength 46000000 N/m^2, Tensile Strength 731000000N/m^2,also the weldability is good.the size of the tubes we used are 26.2mm outer diameter and 3.2mm wall thickess since as per rules we can use tubes minimum of 25mm diameter and 3mm
thickess we selected these dimensions based on the avalabity and stress plot .
Braking system
The main design objectives for the braking system is that it must lock all four wheels, cost effective, simple design ,easy to manufacture, high accuracy and efficiency . We designed our braking which contains four disc brakes connected to pair of front and rear wheels. The pedal is directly actuate the master cylinder of 15mm BORE DIAMETER through a rigid linkBrake disc are of the same diameter for front and rear axis, petal disc size of 200mm, the brake pedal uses 25kg of pedal force .stopping distance is achieved as 2.2 seconds. Callipers and cylinders for braking system are based on components delivered by AMK products. Callipers used have Dual piston and 25mm Bore Diameter Ceramic made low thick Disc, enabled us to reduce mass to maximum level. Flexible Brake House of 1.5FOOT, brake switch of 12volt, Brake light of 12volt, Brake pedal assembly of 6 in pedal. Some other considerations are also made as to fulfil rules of the eventThe vehicle is equipped with a red brake light certified by ISI clearly visible and appear bright in daylight and mounted such that it shines parallel to theGround, not up at an angle. The brake light is activated by mechanical switch. Each independentBrake hydraulic circuit is equipped with a brake light switch, so that no brake, includingCutting brakes may be activated without lighting the brake light.
ENGINE:
The engine we are using is BRIGGS AND STRATON. The specifications of engine we are using have horsepower of 4.5,Displacement of 190cc, super Lo-Tone muffler , fuel capacity of 4.0 qt and 3.79liters,lube oil capacity of 20 oz and 0.6liters,dry weight of 34lb,with cast iron sleeve, OHV, two ball bearings .foam filter, splash lubrication and with magnetron lubrication. Standard size original piston rings may be used. Original Equipment replacement parts may be used ,No cleaning or removing of Aluminum flashing from intake or exhaust ports is done The air intake is relocated, but keeping in mind that only standard parts are to be used to relocate the air filter. The engine is fitted with an alternator to generate electrical energy. The Recoil starter rope is extended to accommodate the driver starting the engine while in seated position. Engine is equipped with a governor, and the Governor is set to 3,500RPM.We didn’t performed any changes in the governor speed.
DRIVE TRAIN:
The main objective of our drive train selection was that improving the drivability of the GO-KART, TO provide the driver as much torque as possible. We are using centrifugal clutch 19mm Shaft bore with 12 Sprocket teeth. Two Bearing Brackets F205 of 25mm ID and F305 of 30mm ID.GEAR RATIO ACHIVED BY US IS 2.4
CLUTCH:
The centrifugal clutch is most common in go-karts it is widely used because it is fully automatic and works depending on speed
DESIGN CONSIDERATION IN CENTRIFUGAL CLUTCH
Wile designing Centrifugal clutch we considered various factors likeinner bore diameter , horse powers ratings, rpm engage and disiengaement ratings, Sprocket and chain sizes.\ etc
STEERING SYSTEMIN OUR GO-KART WE ARE USING SIMPLE MECHANICAL LINKAGE AS STEERING MECHANISM, ADJUSTABLE STEERING ROD SUCH THAT DRIVE CAN ADUST IT ACCORDING TO HIS COMFORT AND MAIN REASON BEHIND IT IS THAT THE DRIVER MUST COME OUT OF VEHICLE FROM FULLY SEATED POSTION WITHIN TIME SPAN OF 4 SECONDS IN THAT SENSE ADJUSTABLE STEERING ROD IS VERY USEFULL.WE ARE USING FRONT KNUCKLE WHICH IS MADE OF STEEL,STEERING WHEEL MADE OF ALUMINUM,STEERING ROD END FRONT KNUCLE BEARING 44610 TAPER ROLLER BEARING AND 60003 ROLLER BEARING
ELECTRICAL SYSTEM
The electrical system include two kill switches OF 12 VOLT DC, a brake light, and a battery powerSource. The kill switches will deactivate the engine ignition. The kill switches will NOTdeactivate the brake light. The brake light operate regardless of the kill switch setting. Thebrake light, and any reverse light and alarm, will be powered whenever the vehicle is in motion.
CONCLUSION:
MECHMANIACS had worked hard for many days and finally completed our design with good values. we made certain changes in our go-kart when compared to others which shows uniqueness of our vehicle.
FRONTANDSIDEVIEW
Stress – displacement diagram
Factor of safety