Final Edr Report

INTERNATIONAL GO-KART CHAMPIONSHIP SEASON 8
LPU SAEINDIA COLLEGIATE CLUB
Organized by:-
TEAM NAME – GAME CHANGERS

TEAM ID – M20018
COLLEGE NAME – Academy of Maritime Education and

Training , Chennai, Tamil Nadu
FINAL DESIGN REPORT OF INTERNATIONAL GO-KART CHAMPIONSHIP

TEAM GAMECHANGER
Academy of Maritime Education and Training, Chennai, Tamil Nadu
Team ID: 19005
Number of member: 12
ABSTRACT
Our project is to DESIGN AND FABRICATION OF GO-KART. Main motto of us is to design a
Go-kart using 2-stroke petrol engine. The maximum speed range of this will be of 60 km.
Material used for the construction of frame is mild-steel. Maximum weight which can be placed
on this will be of 150-200 kilograms. The designing of this go-kart will be in the form of F3
racing car. Drum brake is placed to the rear wheel. Main purpose of this is for racing and used as
re-creation purpose. Pitman arm steering mechanism is used.
Study on Rule book prescribed for go-kart, designing, fabrication and the methodology involved
are studied in this paper. Through different design events, students are able to show interest
towards designing and how it can be fabricated. Design of the Go-kart is based on the rules and
regulations, set by the event organization, International Go-Kart Championship, Season 8. The
Designing of the Go-kart is carried out in the SOLID WORKS and then the analysis is analyzed
in ANSYS 17.0 by considering different types of materials and application of loads. Fabrication
of the go-kart is performed in our University mechanical workspace. And the test drive on the
go-kart is performed to check the performance of the engine, application of brakes and if any
required modifications to be made.
INTRODUCTION
Almost similar to the original go kart, in this project, the main achievement is to make a moving
vehicle. A simple go-kart will be recreated and will be provided with a more advance safety
system and gear shifting technology to improve the kart’s handling and performance. The chassis
are made of steel tube. There is no suspension therefore chassis have to be flexible enough to
work as a suspension and stiff enough not to break or give way on a turn.
HISTORICAL BACKGROUND
American art Ingels is generally accepted to be father of karting a veteran hot rudder and a race
car builder at kurtis kraft, he bulid the first kart in southern California in 1956 .Instantly
popular, karting rapidly spread to other countries , and currently has a large following in Europe .
The first kart manufacturer was an American company, go-kart manufacturing Co. In
1959,McCulloch was the first company to produce engine for karts. Its first engine, the
McCulloch, Mc-10, was an adopted chainsaw two-stroke engine later, in the 1960s, motorcycle
engines were also adapted for kart use, before dedicated manufacturers, especially in Italy
(IAME),Started to build engines for the sport . The determining the design of our go-kart, we
have used the solid modelling software which is Solid works 2014. After analyzing the rulebook
and understanding the concepts of design of chassis as well as other sub-systems, we started out
with our design.
We consider various factors while designing, such as material properties, cost, dimensions,
weight of kart, safety.
Later the design was analyzed using a finite element software which is Hyper works V.12. We
conducted dynamic analysis based on front, side as well as rear impacts. Thus we obtained a
safe, light, aerodynamic design.
Thus, we have achieved an optimum design.
Design And Development

The design of our go-kart is classified into various sub-divisions and is as follows:
Chassis
The material that we have selected AISI 4130 carbon steel. Its material properties are given
below:
1. Ultimate Strength = 432 to 472 MPa
2. Young’s Modulus = 210 GPa
3. Yield Strength = 240 to 400 Mpa.
We have selected the material in the form of hollow tubes of outer diameter = 1 inch and
thickness = 2mm. The chassis are joined together using TIG welding with SS308 filler material.
The AISI 4130 Carbon steel is used because its carbon content is best suitable for TIG.
weld. The design is constructed such that we have incorporated less no of welds, bending of
the material.
The design is done using Solid works 2014 and the line drawings of our assembled go-kart is
shown below:
1. Front View –
Fig. 1. Front View of the go-kart.
2. Right Side View-
Fig. 2. Right Side View of the go-kart.
3. Top View-
Fig. 3. Top View of The go-kart.
4. Isometric View –
Fig. 4. Isometric View of the go-kart.

Engine and Transmission

Engine Type Single Cylinder, 4-Stroke, 2-Valve,
SOHC
Displacement 149 cc
Max Power 13.2 PS @ 8000 rpm
Max Torque 12.8 Nm @ 6000 rpm
No. of Cylinders 1
Cooling System Air Cooled
Valve Per Cylinder 2
Drive Type Chain Drive
Starting Self Start Only
Fuel Supply Fuel Injection
Clutch Wet, Multiple Disc
Transmission Manual
Gear Box 5 Speed
Bore 57.3 mm
Stroke 57.9 mm
Compression Ratio 9.5:1
The driveshaft most suitable for our go-kart is based on a solid shaft of 40mm.
The output from the CVT is transferred to the main shaft using a sprocket-chain system. 25 teeth
sprocket is mounted on the driveshaft and 18 teeth sprocket on the CVT output.
The two pillow block is used to support the shaft end and weight distribution of the kart
is in the ratio is 40:60.
Steering Geometry
We use Drag linkage steering system in our Go-Kart. We use this system as it provides the
optimum steering effect for our Go-kart and is simple in design
The specifications of the steering system are given below:
1. Steering Wheel – 10 inch ( Outer diameter )

2. Steering Column – ϕ18mm (Outer diameter) hollow tube with wall thickness 1.8mm.
3. Wheelbase – 53inch
4. Wheel Track- 34.2 inch
5. Trackwidth – 71.12cm
6. Turning Radius (R) – 2.02m
Following are the equations used to determine the turning angle based on Ackermann theory
given below:
cot δ o−cot δ i=trackwidt h/w h eelbase
The values determined are given below:

1. Inner turn angle = 35 deg

2. Outer turn angle = 25.54 deg
The steering column is adjustable and the steering column is mounted on the front axle using a
Plummer block.
BRAKING SYSTEM
Rear Disc rotor assembly. With the help of single disc rotor we can achieve the braking
effect and the system is axial braking.
The specifications are given below:
l1
Pedal Force (Fp) = l 2/¿ = 800 N
Fd∗¿
We assumed the force applied by the driver as 200N
Pressure developed inside the master cylinder,
P = (Fp /A) = 157.88*104 Pa = Pcal
Force in caliper = Pcal * Acal = 1799.8N
For 1inch bore size
Clamping Force (Fclamp) = Fcal *2 = 3599.6N
Frictional Force ( Ff ) = Fclamp *µbp = 3239.64N
Torque Generated by rotor ( Tr ) = Ff * Reffective = 299.6Nm = Twheel
1. Braking Distance = V2/2µg
At 20km/h = 1.92m
The parts specifications is given below:
1. Caliper – Single piston floating caliper

2. Disc Rotor – Petal drilled disc rotor
3. Outer Diameter of rotor – 180mm
4. Master Cylinder – Bosch
5. Brake Fluid – DOT-3
Finite Element Analysis

The design for our go-kart was then completely analyzed using finite element analysis
software which is “Hyperworks V12”.
The rollcage design which is designed is given below:
Fig. 5. Isometric View of the chassis.
Then we conducted three impact tests which are given below:
Front impact test
Fig. 6. Front impact test.
Rear impact test
Fig. 7. Rear Impact Test.

Side impact test
Fig. 8. Side impact test.
The load applied is 1500N and we attained the maximum stress = 810Mpa and FOS = 2.35.
Results and Conclusion

Through above process we have obtained a safe and strong design.
References
[1] Memo Gidley and Jeff Grist, “Everything you need to know karting”, motor
books publications.
[2] https://www.solidworks.com, Dassault systems
[3] “SAE International journal of materials and manufacturing”, SAE International.
[4] Todd Bridigum,” How to weld “, Motor books publications.
[5] http://www.honda-engines-eu.com - Honda engines
[6] Boyce H. Diggins, “Automotive Steering Systems”, Delmar publications
[7] https://www.engineeringinspiration.com/uk/brakecalcs and James Walker, “Physics of
braking system”.

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INTERNATIONAL GO-KART CHAMPIONSHIP SEASON 8

LPU SAEINDIA COLLEGIATE CLUB

TEAM NAME – GAME CHANGERS

COLLEGE NAME – Academy of Maritime Education and

FINAL DESIGN REPORT OF INTERNATIONAL GO-KART CHAMPIONSHIP

Design And Development

Fig. 1. Front View of the go-kart.

2. Right Side View-

Fig. 2. Right Side View of the go-kart.

Fig. 3. Top View of The go-kart.

Fig. 4. Isometric View of the go-kart.

Engine and Transmission

1. Steering Wheel – 10 inch ( Outer diameter )

cot δ o−cot δ i=trackwidt h/w h eelbase

The values determined are given below:

1. Inner turn angle = 35 deg

The parts specifications is given below:

1. Caliper – Single piston floating caliper

Finite Element Analysis

The rollcage design which is designed is given below:

Fig. 5. Isometric View of the chassis.

Then we conducted three impact tests which are given below:

Front impact test

Fig. 6. Front impact test.

Rear impact test

Fig. 7. Rear Impact Test.

Side impact test

Fig. 8. Side impact test.

Results and Conclusion

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