M.A.M.

COLLEGE OF ENGINEERING AND TECHNOLOGY

Siruganur, Tiruchirappalli – 621 105.

ME8811 Project Work

Project Title:Simulation and analysis of chassis for E-kart deliver vehicle

Register Number Name of student

 812019114039  SATHISH KUMAR G
 812019114042  SHANMUGAM R
812019114043  SHEIK BURHANUDEEN B
 812019114044 SIVABALASUBRAMANIAN K 

Under the esteemed guidance of

Supervisor Name:Mr.MURUGESAN R
Designation: Assistant professor

Version: MAMCET_PR-1.1
 Abstract
• This project proposes the design and development of an E-kart model in its initial
design phase.
• The main objective is to create an electric kart powered by batteries and a motor, which
will not emit any hazardous gases that can harm the environment.
• To achieve this, a brush-less direct current (BLDC) motor and lithium-ion batteries are
used. These components are known to be reliable and efficient.
• The chassis of the kart is made of AISI 4130 material, which is strong and lightweight.
• The design includes the design and calculation of all components, such as the batteries,
motor, brake, etc.
• The maximum speed of the kart is 40 km/hr. Additionally, the overall weight of the kart
is kept to a minimum in order to maximise its speed and efficiency.
• The design of the kart also takes into account safety aspects, such as the brake system
13/06/2023and the overall
Project Work -stability of ofthe
M.A.M. College kart. and Technology, Siruganur, Tiruchirappalli – 621 105.
Engineering 2
 Introduction
• The first go-kart was invented by Art ingles in 1955, the go-karts are
powered by fossil fuels which leads to emission of harmful
hazardous gases like carbon monoxide, nitrogen oxides,
hydrocarbons, etc.
• Whereas E-kart are powered by batteries and motors so there will
not be any emission ans do not cause any harm to atmosphere.
• In this project we aimed to design and develop a electric kart and
this paper represents the design and calculation of the E-kart

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 3
 Block Diagram

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 4
 Parameters of concern

Sl. NO. Parameters Identified Remarks

1 Max and min Deflection Initial identification

2 Max and min stress Initial identification

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 5
 Literature Survey (Minimum 05 papers)
Sl. No. Details of the paper

1 ELECTRIC VEHICLE TECHNOLOGY EXPLAINED” by J. Ma, John Wiley and John Lowry
published by John Wiley and sons
limited.
Year of publication : 2017
Objective Methodology Result

Fabrication & Testiing EV's energy consumption Not Reliable Backup

per kilometre, driving

Sl. No. Details of the paper

2 “DESIGN AND FABRICATION OF ELECTRIC GO-KART”

published on IRJET. Year of publication : 15 SEP 2020
Objective Methodology Result

Design a go kart Develop carry more weight Achieved

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 6
 Literature Survey
Sl. No. Details of the paper

3 D. Karale, S. Thakre, M. Deshmukh “DESIGN AND

ANALYSIS OF ELECTRIC VEHICLE”, IJOI vol.4. Year of
publication : 2020
Objective Methodology Result

EV chassis Design Special attachment added with chassis

sprayer attachment
For agri purpose

Sl. No. Details of the paper

4 Electrical Motors for Electric Vehicle – A Comparative Study” by P. Bhatt,

Hemant Mehar, M. Sahajwani published on SSRN Electronic Journal.

Objective Methodology Result

Electric motor study Selection of motor To be select based on Speed

range, gross weight ect
13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 7
 Inferences drawn

1. Optimization of frame structure based on load requirements was enabled with Fusion 360
Generative Design.

2. This advanced technology produced a lightweight yet strong frame structure for the load placed
on it.

3. The process was complicated and time-consuming, but the end results were worth it.

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 8
 Proposed solution

1. The chassis and body frame were selected from AISI 4130 material, a grade of
chromoly steel, as it is well-known for its strength and light weight properties.
2. The 3D model was developed in Fusion 360, a popular 3D modelling software, and
then thoroughly analyzed using the Fusion 360 static and vibration analysis tools,
which enabled to have a highly accurate simulation of the behavior of the frame and
chassis under different conditions.
3. This ensured that the design will be optimized for the intended purpose and
provided the confidence that the frame and chassis were able to meet the required
standards for safety and performance.

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 9
 Steps to carryout the project
Step No. Step Name Remarks

1 Literature Survey Completed

2 Material Selection For Frame Completed

3 Modelling Completed

4 Simulation Completed

5 Test Report Generation Completed

6 Result and discussion Completed

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 10
 Flow chart of Steps to carryout the project

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 11
 Proposed 3D Model

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 12
 Proposed 3D Model

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 13
 Result & Discussion
Static Stresses for the Frame :

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 14
 Result & Discussion
Static Stresses for the Frame :

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 15
 Result & Discussion
Static Stresses for the Frame :
• The simulation module in Fusion 360 was used to perform a static stress analysis on
the e-kart bike frame, which was imported from the design module.
• The material assigned to the frame was AISI4130 high strength alloy. The mesh size
was set to a minimum element size of 20.
• The meshing process resulted in 200832 nodes and 111426 elements. The front and
back axles of the e-kart bike were fixed and all the degrees of freedom were
constrained
• A force load of -50 N was applied along the Y axis direction.
• The safety factor of the frame was 8, which met the design requirement.
• The maximum third principal stress was 0.09991 MPa and the maximum displacement
was 0.01206 mm. The results showed that the frame could withstand the applied load
without failure.

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 16
 Result & Discussion

Modal Frequencies analysis for the

Frame :

Frequency Participation X Participation Y Participation Z

Mode 1: 0.1542 Hz 0.0064 0.0034 0

Mode 2: 0.2222 Hz 0.003 0.0015 0.0002

Mode 3: 0.3077 Hz 0.0025 0.0003 0.0006

Mode 4: 34.73 Hz 0 0 20.8086997

Mode 5: 42.32 Hz 36.0668004 6.41689971 0

Mode 6: 60.34 Hz 0 0 18.9117

Mode 7: 71.66 Hz 0.0095 0.0028 0.0004

Mode 8: 74.79 Hz 0.0003 0 4.37400006

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 17
 Result & Discussion

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 18
 Result & Discussion

Modal Frequencies analysis for the Frame :

• After the static analysis done the nodel analysis were performed for the vibration and damping study
of e kart model.
• The mesh size was set to a minimum element size of 20. The meshing process resulted in 200832
nodes and 111426 elements.
• The front and back axles of the e-kart bike were fixed and all the degrees of freedom were
constrained. A force load of -10 N was applied along the Y axis direction.
• The model results were for the1 Mode 1: frequency 0.1542 Hz and the deviation absorbed in X
0.0064 Y 0.0034 Z 0 direction all the other mode results are detailed in the table.

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 19
 Conclusion

• In conclusion, the electric kart model is a great step forward in creating a sustainable and efficient
mode of transportation.
• The design and development of the kart were carried out, taking into account the important aspects
of speed, efficiency, and safety.
• The kart has been thoroughly tested using simulation modules in Fusion 360, and the results of the
simulation show that the frame could withstand the applied load without failure and the model meets
the design requirements.
• The use of eco-friendly components and a robust chassis made of AISI 4130 material ensures that
the kart is both reliable and efficient. It is an excellent option for transportation that has a low
environmental impact, making it an ideal solution for a better tomorrow.

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 20
 Bibliography
[1] Prof. Nirmal Chohaun has written report on “DESIGN AND FABRICATION OF ELECTRIC GO-KART” published on
researchgate.com
[2] “ELECTRIC VEHICLE TECHNOLOGY EXPLAINED” by J. Ma and John Lowry published 2012 by John Wiley and sons
limited.
[3] D. Karale, S. Thakre, M. Deshmukh “DESIGN AND ANALYSIS OF ELECTRIC VEHICLE”, IJOI vol.4, 1 OCT 2020. [
4] Koustubh Hajare, Yuvraj Shet, Ankush Khot, “A Review Paper on Design and Analysis of a Go-Kart Chassis”
International Journal of Engineering Technology, Management and Applied Sciences, ISSN 2349 -4476, Volume 4,
Issue 2, Feb 2016
. [5] “Design and Analysis of Steering Mechanism for Electric-Solar Vehicle” A. Haik, M. A. Hmed, M. A. Ubin, 2017
. [6] “A FUTURE FOR SOLID STATE BATTERIES” by J. Janek, Wolfgang G. Zeier in 2016
. [7] “Electrical Motors for Electric Vehicle – A Comparative Study” by P. Bhatt, Hemant Mehar, M. Sahajwani
published on SSRN Electronic Journal, 3 April 2019.
[8] SKDC season IV Rulebook by “SOCIETY OF MECHANICAL AND AUTOMOTIVE ENGINEERS”. [9] Mahindra-Treo and
E-Alfa mini eBorchure by “TECH MAHINDRA”.
[10] Maxi E-Rikshaw eBrochure by TRINITY ELECTRIC PVT. LTD

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 Thank You Slide

13/06/2023 Project Work - M.A.M. College of Engineering and Technology, Siruganur, Tiruchirappalli – 621 105. 22