Available online at www.sciencedirect.

com

ScienceDirect
Materials Today: Proceedings 2 (2015) 1707 1713

4th International Conference on Materials Processing and Characterization

Design and Development of Foldable Kart Chassis

Akash Chaudhary Raghuvanshi1,Tushar Srivastav1, Raghvendra kumar mishra1
1
Department of Mechanical Engineering, School of Engineering,
Gautam Buddha University, Gautam Buddh Nagar ,201310

Abstract

The population of world is increasing day by day and so the area is decreasing, just in the stage of a compact world. The world is
going towards the compactness, where the all things are going to compact. The time is to think about vehicle which can be fol ded
easily and can be taken everywhere as a luggage. This paper is about the design and development a GO KART named as
ASHVA which can be folded by its mid with the help of a joint that connected between its two chassis front chassis-rear
chassis. The strength analysis of the joint has been done with the help of ANSYS software. Further the development had been
done after the designing and analyzing the joint of chassis .

2014Elsevier
2015 The Authors.
Ltd. AllElsevier Ltd. All rights reserved.
rights reserved.
Selection andpeer-review
Selection and peer-review under
under responsibility
responsibility ofconference
of the the conference committee
committee members
members ofInternational
of the 4th the 4th International
conferenceconference on
on Materials
ProcessingProcessing
Materials and Characterization.
and Characterization.

Keywords:GO KART, ANSYS

Introduction

Kart are used to just take the experience of racing cars. Mostly they are very entertaining vehicles in the markets.
Karts are likely the basic concepts of car nothing else. As the speed of kart is just varies on the power of engine and
how much fuel it takes. The chassis of kart is made up from the mild steel and the joint of kart had been made up of
mild steel . This joint gives more power and stability to the vehicle. Student competition based on the product they
designed and fabricated is a good activity carried out by university students.Here mechanical chain is used for
transmit the power from the engine to the axel of kart.

* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 .

E-mail address:akash6180090@gmail.com

2214-7853 2015 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing
and Characterization.
doi:10.1016/j.matpr.2015.07.004
1708 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713

Generally karts speed varies from 45 Km/Hr 65 Km/Hr and this kart also had a speed of 52 Km/Hr. As joint gives
the support to the both chassis front as well as it also helps to bears maximum force on it so that chassis have good
strength and can bear maximum weight in comparing of other karts. For less turning radius we used simple rack and
pinion. National Go-Kart championship is a platform where nation comes together with bringing new ideas of their
minds in automobile field. This completion gives the basic knowledge of car and increases manufacturing skills of
students. There is not much research about go-kart design. Most of the research is about the safety and injury. Risk
compensation theories hypothesize that if individuals use safety belts, they will drive in a more risky manner than if
they do not use safety belts due to an increased perception of safety.

2. Conceptual Design and Analysis

Table 1
1 Specification
2 Material selection
3 Design and structural analysis
4 Component selection
5 Test drive

1.1 Specification and description of the kart

Designing of any component is a very tough task for any engineer because it needs a deep thinking and calculation,
a good design needs a very accurate calculation. After this whole process analysis is done over design so as to assure
that there is no deformation or failure of the component on deployment of the load on the kart. The design can
sometimes fail in analsys after which the product needs to be redesigned. The basic idea behind manufacturing this
type of design is to give the comfort and compact ability to the driver, so that driver can feel safe and comfortable to
enjoy the every ride of kart. For making a kart/car the following subsystems such as chassis subsystem steering
subsystem, wheel and tyre subsystem, brake subsystem and power train subsystem should be designed and
fabricated. For a better karting experience, rack and pinion steering system and 190 mm disc brakes were used and a
suitable gear ratio of 2.7 was chosen.Wheel base of the kart was kept 1,257.5 mm and the track width of kart is
1,032.5 mm. The ground clearance of the vehicle is 72.5 mm,weight of kart as measured is around 135.7 Kg without
driver. The tyre subsystem was made by front tyres of 10 inch outer diameter and rear tyres of 13 inch outer
diameter.

Figure 1.Complete chassis of kart

 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713 1709

Figure 2. Front chassis analysis

Figure 3.Rear chassis analysis

Dimension of folding joint is given below-

An innovative thing is made up of many creative ideas and dimension

Female part of joint-

Male part of joint-
1710 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713

Figure 4. Folding joint designed using SOLIDWORKS 2010 to make chassis foldable

1.2 Material selection

A design gets its power by applying the best material on it. Selection of material plays a major role in strength and
safety of the product . One of the most important and basically the skull of the kart is the chassis subsystem. The
chassis of the kart was developed with an igniting idea of a fish body .A fish body is a perfect aerodynamic natural
structure ,one can get inspired with .The chassis of the kart was developed by using AS-202 Stainless steel round
tubes having 30mm outer diameter & 25mm inner diameter.

Following are the properties of stainless steel round tubes which helped in the selection of SS-202 as a suitable
material for manufacturing the chassis of the kart :

Table 2. Properties of SS 202.

Property Value
tensile strength 515 Mpa
Yield strength 275 Mpa,
elastic strength 207 Mpa

Mild steel shaft having diameter 27.4 mm was chosen to be used as the axle of the kart so as to bear the bending
stresses tran smitted due to shaft components like gears, bearings , disc brakes etc. Picture of complete axle is
shown in figure
 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713 1711

Figure 5. Complete axle of the kart with axle components

1. Development phase of the kart

The development phase of the kart involves fabrication ,assembly and testing of the kart. Beginning with the
fabrication part, the structure or chassis of kart was fabricated by using electric arc welding. The electric arc
welding was the only cheap and reliable option available for fabrication in order to adhere with the low cost of the
vehicle. Figure shows the electric arc welding of kart chassis being performed.

Figure 6. Electric arc welding being performed on the chassis

After the fabrication phase , assembly of the kart was carried on. 8 point hardness lock nuts were used for fastening
purpose at every point of the assembly due to reliability of the nuts. Firstly, the rear axle was assembled and tyres
were mounted on the axle . now , when the rear axle is mounted , assembly of engine and chain sprocket takes
place. Figure shows the assembled engine on the frame
1712 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713

Figure 7.
After the successful assembly of the kart ,testing phase plays an important role in the completion project .testing of
takes place in every subsystem was systems. firstly testing of steering was done by eliminating the excessive free
play and testing the turning radius of the kart. Brake test was done by calculating the braking distance. On
calculation the braking distance turned out to be 98cms. Wheel alignment was also tested to ensure that all the
wheels (front and rear) are properly inclined. The figure below shows the pictures of complete engineering
designand completed kart prepare at Gautam Buddha University , Gautam Buddh Nagar.

Figure 8. Complete design of vehicle designed in SOLIDWORKS 2010

 Akash Chaudhary Raghuvanshi et al. / Materials Today: Proceedings 2 (2015) 1707 1713 1713

Figure 9. Front view of kart

(a) (b)
Figures 10. (a) and (b) isometric views of kart

Conclusion-
A vehicle can be made with this type of joint and can be easily folded by its mid to acquire less area. This type of
joint also helps to make any vehicle compactable.

Reference-
1. A. A. Faieza*, S. M. Sapuan, M. K. A. Ariffin, B. T. H. T. Baharudin and E. E. Supeni[2009],Design and
fabrication of a student competition based racing car.Scientific Research and Essay Vol. 4 (5) pp. 361-366.
2. Biancolini Marco Evangelos, Baudille Riccardo, Reccia Luigi,Integrated multi-body/FEM analysis of vehicle
dynamic behaviour. Paper code: F02I112.
3. Ho Yoong Chow[2001],Go-karts design and construction based on theoretical and experimental findings.
4. ABERDEEN LIM JIAN RONG[2011],Low cost fibreglass Go-kart.
5. Kristaps Vitols, Nadav Reinberg, Alvis Sokolovs, Ilja Galkin[2010],Drive selection for electric kart.,Topical
Problems in the Field of Electrical and Power Engineering Prnu, Estonia,
6. M.S.M.Sani, M.T.Arbain, M.M.Noor, G.L.Ming, M.H.Zohari, C.K.E Nizwan & T.T.Mon[2010],Stress analysis
and model transient response of car chassis.International Conference on Advance Mechanical Engineering
(ICAME09).