ISNEE 6th GKDC

COMPUTER AIDED ENGINEERING REPORT

TEAM NAME: BLACK CAPS

TEAM ID: 20180577
COLLEGE NAME: COLLEGE OF TECHNOLOGY
AND ENGINEERING, UDAIPUR
CITY: UDAIPUR, RAJASTHAN
COMPLETE CAD MODEL OF THE VEHICLE
The frame is designed to meet the technical requirements of
competition the objective of the chassis is to encapsulate all
components of the kart, including a driver, efficiently and safely.
Principal aspects of the chassis focused on during the design and
implementation included driver safety, drive train integration, and
structural weight, and operator ergonomic. While designing chassis the
1st priority was given to driver safety as per the rule book. By
the competition rules and analysis in ANSYS, the design was assured.

CHASSIS DESIGN CONSIDERATIONS

(ACCORDING TO RULE BOOK)
The mountings and designing of chassis should be such that there
should be minimum 3 inches (gap) clearances between the driver and
any component of the vehicle in static and dynamic condition – hands,
torso, thighs etc. The chassis must accommodate the driver, as well as
the engine. While a problem with structural integrity or stiffness can
usually be solved by simply varying the wall thickness or diameter of a
tube, the challenge of fitting all components into the smallest space
possible rarely has clear or straight forward solutions.

DESIGN METHODOLOGY
Methodology gives the brief idea to what the method that has been
adopted throughout the project. The flow of the whole project is
illustrated as in Figure in the following page.

STRUCTURAL ANALYSIS
JUSTIFICATION OF LOADS FOR
ANALYSIS OF FRAME: The next stage in the design process is to analyse
the frame & add features accordingly. FEA (Finite element analysis) is
then done on the roll cage to make sure that the proposed design is
strong enough
to withstand the loads of collision & rollover. For these reasons it was
deemed that there should be an analysis of front impact, rear impact,
side impact & rollover. However before the analysis are performed,
an estimation of the loading forces exerted on the go-kart must be
completed.
Impact time estimation: After a long research and with references of
many research and technical paper we found that the impact time lies
in between 150000ms to 200000ms. So the impact time taken
for the force estimation is 180000ms.
DESIGN ANALYSIS AND
CALCULATION
Calculation of Impact force: It is assumed that after collision with rigid
stationary object; the go-kart comes to rest. The estimation of impact
force was done by using “Impulse- Change in momentum theorem”.

Impulse (F) = G*m*g

Where m = mass of Go-kart with driver weight
G = 4, for front impact
3, for rear impact
2, for side impact

FRONT IMPACT TESTS:

In front collision test, the go-kart collides with a stationary rigid wall
and comes to rest. So, the load is applied on four points of Crumple
zone members and DOF’s were constrained in the back portion of the
go-kart.

Impact load calculations regarding front impact test are as follows:

M (mass of the vehicle) = 170 kg
Driver included)

Front impact load = G*m*g = 4*170*9.81 =6670.8 N

REAR IMPACT TEST:
In rear collision, the go-kart is assumed to be stationary, fixed and
another go-kart is moving with same mass and collides with the former
go-kart. Force is applied on rear portions of go-kart and all DOF’S of
front were constrained.

Rear impact load (F) = G*m*g = 3*170*9.81 =5003.1 N

SIDE IMPACT TEST:

As a side impact is most likely to occur, with the go-kart hit by another
go-kart, it was assumed that neither go-kart would be a fixed and
stationary object. Referring to the automotive industry safety testing,
which also makes an equivalent assumption, the impact force was
assumed to be half of that on head on collision with the fixed object. In
side impact test, the forces were applied on the side members in
contact with other go-karts during collision and all degree of freedom of
points on the other side were constrained

Side impact load (F) = G*m*g = 2*170*9.81 = 3335.4 N

ANALYSIS:
Normal Force on Stub Axle:
N = m *g
=50 * 9.81
= 490.50 Newton

Lateral Force on Stub Axle:

Lateral Force = mv^2/r
= 1035 N
Tractive Force:
Force due to traction = μ* Normal Force
= 294.3 N
Methodology for designing Stub Axle:
Firstly, before switching to Software’s (Solid works, Ansys ) the
background calculations and analysis of failure of Axle under loads were
accompanied. On the basis of values obtained by theoretical
calculations stub axle was designed on CAD software. After this further
analysis on software’s were done which has provided results after
which iterations were made and conclusion was drawn.

Structural analysis of stub axle:

CAD geometry was imported in ansyssoftware in .IGES format.
Material specification of stub axel imported in software:

Property Value

Density 7.88 g/cc

Carbon % 0.36-0.44

Ultimate Tensile strength 700-1000 Mpa

Yield Strength 495-940 Mpa

Analysis at Normal Force( Self weight ):

Since mass in front was considered 50 Kg, thus weight on one wheel
stub axle would be half of front Weight.
Load Conditions:
The Load applied and boundary conditions are as follows:
Red colour shows the load applied. Load of 500 Newton was
applied downwards.
The pivot point was fixed and rigid assuming that there no
deformation occurs at the eye. Blue colour shows the fixed
surfaces.

LOAD CONDITION

DEFORMATION PLOT
 STRESS PLOT

0.000947 mm of deformation is occurred when the load of 245.25 N

was applied. Internal stress generated due load applied was 176 Mpa.

Analysis at Lateral Force (While turning):

Lateral Force calculated was 1035 N.
Red colour shows the load applied. Load of 517.5 Newton was
applied in Forward direction.
The pivot point was fixed and rigid assuming that there no
deformation occurs at the eye. Blue colour shows the fixed
surfaces.
DEFORMATION PLOT
 STRESS PLOT

SHAFT CALCULATIONS:
IN TORSION:
For torsion, Torque at first gear will me maximum, considering that the
rear tires are locked and vehicle is started at 1st gear, thus this
blockingssss will create the stress generation in the shaft somewhere.
One end is fixed and another end moment is applied.

Moment =26 N-m

LOAD CONDITION
DEFORMATION PLOT

STRESS PLOT
Design of Wheel Hub:
Objective: The aim of designing hub was to fabricate a lightweight
wheel hub with better strength and a good manufacturability.

DEFORMATION PLOT

STRESS PLOT