i

A Project Report on

Design and Fabrication Report of Go Kart

Submitted in partial fulfilment of the requirement for the award of
the Degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Under

JNTU HYDERABAD

By
MOHD AZHAR UDDIN (17M25A0302)
ABDULLAH BIN SAYEED (17M25A0304)
MOHAMMED TAQIUDDIN ZAID (17M25A0325)
MOHD FURQAN UDDIN (17M25A0332)
MOHAMMED BASITH QURESHI (15M21A03M9)
Under the Esteemed Supervision of
Mr. Mohd Yousuf Ahmed
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY

(Accredited by NAAC, Accredited by NBA, Approved by AICTE & Affiliated to JNTU,

Hyderabad) Survey No. 32, Himayath Sagar, Hyderabad-500091, India.

2015-2017

ii
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that major project report entitled “Design and Fabricaton Report
of Go Kart”, is a bonafide record of the work successfully completed and
submitted by

MOHD AZHAR UDDIN (17M25A0302)

ABDULLAH BIN SAYEED (17M25A0304)
MOHAMMED TAQIUDDIN ZAID (17M25A0325)
MOHD FURQAN UDDIN (17M25A0332)
MOHAMMED BASITH QURESHI (15M21A03M9)

Under the guidance of Mr. Mohd Yousuf Ahmed, Assistant Professors in

Mechanical Engineering Department, for the requirement of partial fulfilment for the
award of degree of Bachelor of Technology in Mechanical Engineering during
the academic year 2015-2019 from JNTU- Hyderabad.

Mr. Mohammed Asif Dr. Syed Azam Pasha Quadri

Internal Guide Head of Department

Dr. Mohammed Yousuf Ali

Principal

External Examiner
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

iii

DECLARATION

We hereby declare that the thesis entitled “Design and analysis of

Steering assembly for go kart” which is being submitted by us in partial
fulfilment for the award of Bachelor of Technology in the Department of
Mechanical Engineering at the Lords Institute of Engineering and
Technology, Telangana-500091, is the result of investigations carried out by
us under the Guidance of Mr. Mohd Yousuf Ahmed, Assistant Professors in
Mechanical Engineering Department, Lords Institute of Engineering and
Technology.
The work is original and has not been submitted for any Degree for
this or any other university.

A NASRULLA KHAN (17M25A0302)

ABDULLAH BIN SAYEED (17M25A0304)
MOHAMMED TAQIUDDIN ZAID (17M25A0325)
MOHD FURQAN UDDIN (17M25A0332)
MOHAMMED BASITH QURESHI (15M21A03M9)
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

iv

ACKNOWLEDGEMENT

Abdul Madani Mirza Omer Mohd. Amair

(not a Muqther Baig
15M21A03H1
member Adnan Altaf Khan 15M21A03G0
7893014886
anymore) 15M21A03E4 15M21A03E6 9700305050
15M21A03E3 8801188976 8686714621 Omermuqther1998 amairrockkzz@g
9700209282 Adnanai.aa154@gm Shoeb1012@gmail. @gmail.com mail.com
abdulmadani ail.com com
45@gmail.co
m

The successful completion of this project involves many people and we

are extremely grateful to lecturers in mechanical engineering department for
their excellence guideless right from selection of project and for
encouragement throughout the completion of the project.
We express our sincere thanks to my supervisor Dr. Syed Azam Pasha
Quadri and Supervisor Mr. Abdul Junaid, Assistant Professors, Lords
Institute of Engineering & Technology. The main source for helping in
selection our project and also suggested the suitable direction for our
project. They guidance showed the path towards the successful completion
of project.
We derive great pleasure in expressing our sincere gratitude to our Principal
Dr. MOHAMMED YOUSUF ALI for his timely suggestions, which helped us
to complete this work successfully.
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

PROJECT ASSESSMENT PROCESS

PSO

Professional Skills

Problem – Solving Skills

Course Name: C426 Project Work of Study: 2018 – 2019

Exhibit good teamwork skills and serve as effective members of

C426.1 multi- disciplinary project teams

Articulate and justify technical solutions to diverse audiences

C426.2 through oral, written, and graphical communication.

Analyse the importance of professional and ethical

C426.3 responsibilities of mechanical engineers.

Experimentally analyse the innovative approach with respect

C426.4 to research & development.

PEO

PEO 1 Shall apply fundamental and advance knowledge skills in basic and
engineering science and in mechanical engineering to find suitable solution
to technological challenges and problem in various areas of engineering and
real life areas using modern tools.

PEO 2 Shall practice mechanical engineering in a responsible, professional,

and dedicated manner by functioning effectively either as an individual or as
a member of plenty disciplinary team, for the benefit of the industry and
society at large without detriment to environment and sustainable
development.

PEO 3 Shall acquire good job opportunities in industries or pursue

higher studies.

PEO 4 Shall develop the ability to engage in lifelong learning, research and
development in a responsible, professional, dedicated and ethical manner
for the benefit of the industry and society at large.
 vi

ABSTRACT

A Go-kart is a small four wheeled vehicle. Go-kart, by definition, has

no suspension and no differential. They are usually raced on scaled
down tracks, but are sometimes driven as entertainment or as a
hobby by non-professionals. 'Carting is commonly perceived as the
stepping stone to the higher and more expensive ranks of motor
sports. Kart racing is generally accepted as the most economic form of
motor sport available. As a free-time activity, it can be performed by
almost anybody and permitting licensed racing for anyone from the
*age of 8 onwards. Kart racing is usually used as a low-cost and
relatively safe way to introduce drivers to motor racing. Many people
associate it with young drivers, but adults are also very active in
karting. Karting is considered as the first step in any serious racer's
career. It can prepare the driver for highs-speed wheel-to-wheel racing
by helping develop guide reflexes, Precision car control and decision-
making skills. In addition, it brings an awareness of the various
parameters that can be altered to try to improve the competitiveness
of the kart that also exist in other forms of motor racing.

Index Terms— Go-kart, Racing, Design, Frame, Analysis, Steering System,

Braking System, Engine, Transmission, Innovation.
 vii

CONTENTS`
Certificate ii
Declaration iii
Acknowledgement iv
Abstract vi
List of Figure x
List of Tables xiii
Abbreviations xiv
 Chapter 1
1.Introduction 1
1.1 Background 2
1.2 Problem statement 4
1.3 Significance of our project 4
 Chapter 2
2.1 literature review 6
2.2 History 6
2.3 design objective 6
 Chapter 3
3. Objective & problem statement 9
Chapter 4 Methodology
4.1 Design calculation 12
4.1.1 Chassis 12
4.1.2 Wheel hub 13
4.1.3 Steering 14
4.1.4 Transmission 16
4.1.5 Braking 17
4.2 3D Modelling 19
4.2.1 Chassis 19
4.2.2 Wheel hub 20
4.2.3 Steering 21
 viii

4.2.4 Transmission 22
4.2.5 Braking system 23
4.3 Analysis
4.3.1 Chassis 24
4.3.2 Wheel hub 25
4.3.3. Transmission 26
4.3.4 Braking system 26
4.4 Fabrication 29
4.4.1 Chassis 29
4.4.2 Material selection 30
4.4.3 Wheel hub 32
4.4.4 Steering 34
4.4.5 Transmission 36
4.4.6 Braking system 39
4.6 Assembly of mechanical components 40
4.6.1 Chassis 40
4.6.2 Wheel hub 41
4.6.3 Steering 44
4.6.4 Transmission 45
4.6.5 Braking 46
4.7 Assembly of electrical component 46
4.8 Final project model 47
4.8.1 Chassis 47
4.8.2 Wheel hub 48
4.8.3 Steering 48
4.8.4 Transmission 49
4.8.5 Braking 49
Chapter 5 Result
5.1 Result & discussion 51
Chapter 6 Conclusion 53
 ix

6.1 conclusion 54
6.2 Future scope 54
 x

List of Figures

Fig:1. Go Kart

Fig:2. 2D CAD design with dimensions

Fig:3. Front type

Fig:4. Steering system design

Fig:5. Rear axle

Fig:6. 3D model design rendered image of chassis in solid works 2018

Fig:7. Hub for front wheel assembly

Fig:8. Front wheel

Fig:9. Rear hub

Fig:10. Steering system design

Fig:11. Block diagram of transmission

Fig:12. 3D modelling of transmission system

Fig:13. Disc plate

Fig:14. Applied front load:8000N

Fig:15. Applied rear load:4000N

Fig:16. Applied side load:6000N

Fig:17. Stub axle hub deformation

Fig:18. Stub axle stress

Fig:19. Maximum deformation wheel hub

Fig:20. Equivalent stress wheel

Fig:21. Total deformation axle

Fig:22. Equivalent stress axle

Fig:23. Analysis of axle rod

Fig:24. Maximum temperature generated in stainless steel disc plate

Fig:25. Thermal strain stainless steel disc plate

 xi

Fig:26. Maximum deformation in stainless steel disc plate

Fig:27. Maximum stress developed in stainless steel disc plate

Fig:28. Pipe bent for chassis

Fig:29. Chassis

Fig:30. Test report of chassis material

Fig:31. Fabrication of hub

Fig:32. Fitting of front hub

Fig:33. Rear hub

Fig:34. Steering system design

Fig:35. Adjustable steering column

Fig:36. Transmission setup

Fig:37. BLDC motor

Fig:38. BLDC motor controller

Fig:39. Kill switch

Fig:40. Battery

Fig:41. Brake pads

Fig:42. Master cylinder with pedal

Fig:43. Chassis with sheet for cockpit

Fig:44. Seat fitting

Fig:45. Welding

Fig:46. Chassis assembly

Fig:47. Part of front wheel hub

Fig:48. Part of front wheel hub

Fig:49. Rear hub

Fig:50. Front wheel hub

Fig:51. Assembly of steering

 xii

Fig:52. Welding of steering

Fig:53. Transmission arrangement

Fig:54. Axial

Fig:55. Fitting the calliper

Fig:56. Bleeding the disc brake

Fig:57. MCB

Fig:58. Connection

Fig:59. Kill switch

Fig:60. Circuit diagram

Fig:61. Chassis with hubs welded

Fig:62. Wheel hub

Fig:63. Steering system

 xiii

List of Table

1. Braking specification
2. Material properties
3. Transient thermos-elastic analysis result table
4. Properties of material
 xiv

Abbreviation

2D – Two Dimension

3D- Three Dimension

Ah – Amp Hour

BLDC- Brushless Direct Current

CAD- Computer Aided Designing

DC – Direct Current

Kmph – Kilo Meter Per Hour

M – Meter

MCB –Miniature Circuit Breaker

MM- Millimetre

N- Newton

NM –Newton Meter

NASCAR- National Association Of Stock Car Auto Racing

P- Power

PMDC- Permanent Magnetic Direct Motor

R- Radius

SQMM- Square Milter

T – Torque

V -Voltage
1

Chapter 1
Introduction
 2

1. Introduction

The automotive chassis is tasked with holding all the components

together while driving, and transferring vertical and lateral loads,
caused by accelerations, on the chassis through the wheels. Most
engineering students will have an understanding of forces and torques
long before they read this. Some people stress full with material choice
but once you are familiar with this it is the key to a good space frame.
While this will make the design better it can still benefit from this
more general design principle. The design section of the book will talk
more about these items. We designed a CAD model of the chassis on
the 3D modelling software. Using this design software allowed the
team to visualize the design in 3-D space and reduce errors in
fabrication. The main criterion in chassis design was to achieve
perfect balance between a spacious and ergonomic driver area with
easy ingress and egress, and compact dimensions to achieve the
required weight and torsional rigidity criteria. Following this criterion,
the required dimensions were roughly set using a virtual template to
achieve the necessary clearances in case of a rollover situation. After a
series of design changes and subsequent calculations, the final
chassis design was decided upon.
 3

Fig:1. Go Kart

The design process of the vehicle is iterative and is based on various

engineering and reverse engineering processes depending upon the
availability, cost and other such factors.

So the design process focuses on following objectives:

 Safety
 Serviceability
 Strength
 Ruggedness
 Standardization
 Cost
 Driving Feel and Ergonomics
 Aesthetics
 Durability
 Light Weight
 High Performance

1.1. Background

Many vehicles in production today are powered by fossil fuels, however as

the prices of this fuels continue to rise, their future availability not certain,
and the costs involved in servicing fuel powered engines has also risen. The
fluctuating availability of the commodity (petroleum) due to other factors
like wars in the middle east has made it hard to predict the reliability of
petroleum in the near or long term future.

From these experiences we realized that the world need a revolution or a

complete overhaul in the transport system to complete electric systems. In
that case therefore, there is need to design vehicles that are powered by
electricity. Moreover, electric vehicle are more efficient compared to fuel
powered vehicles. It is also cleaner and thus ensures less pollution and
hence a clean environment.
 4

As compared to fossil powered engines EV have got simplified parts and

connections. A motor in itself is so simple as compared to the engine block
of petrol and diesel powered vehicles which is made up of so many parts.

In the world right now there are electric vehicles available in the market like
the Tesla. This brand of cars like many other EV from other companies are
very expensive with the Tesla retailing at USD 100,000. This is a very large
amount of money that can only be raised by a few people. There is a need
for a cheaper EV in our markets.

The cheaper EV available in the markets have their shortcomings in that

most of them run at low speeds compared to fossil powered and can only
operate for a relatively short period of time before the batteries get depleted.

1.2. Problem Statement

Most car owners in Kenya would like to cut on the cost of buying,
maintaining and the running of their vehicles. The owners can be owning
cars for commercial and personal use and or for fun e.g. racing. It is so
hard to have that when the engines are either petrol or diesel engines which
are generally expensive to maintain and run.

Other car owners to be will opt for another vehicle other than EV because of
the absence of the charging stations in Kenya which is necessary provided
the low range of the current EV. Global warming that has seen the world
temperatures to rise especially in the poles has been attributed to the fossil
fuels being used in the petroleum engines especially vehicles due to their
monstrous number in the world.

The goal of this project was to come up with a handmade EV that uses
locally available subassemblies. We focused on improving the range by
reducing the weight of the vehicle. We also made sure that we met the SAE
and the Formula Student rules that governed us through the design. We
tried as much as possible to cut the cost of EV by designing it using the
locally available materials.

1.3. Significance of Our Project

For a successful project, an engineering solution for the following needs
statement must be developed. “There is a need for a vehicle that is cheap,
 5

easy to maintain and operate. The vehicle should have less pollutants
released into the environment either solid, liquids or gases during its idle
and operation time. The vehicle should be safe to the user and to the people
around it. It should also be easy to use and finally it should be both
appealing to the user and satisfactory to their needs’’. We therefore, used
our knowledge in engineering to provide some of solutions to the above
needs.
6

Chapter 2

Literature Review
 7

2.1 Literature Review

A chassis consists of an internal framework that supports a man-made

object in its construction and use. It is analogous to an animal's skeleton.
An example of a chassis is the underpart of a motor vehicle, consisting of
the frame (on which the body is mounted). If the running gear such as
wheels and transmission, and sometimes even the driver's seat, are included
then the assembly is described as a rolling chassis. The chassis takes a load
of the operator, engine, brake system, fuel system and steering mechanism,
so chassis should have adequate strength to protect the operator in the
event of an impact. The driver cabin must have the capacity to resist all the
forces exerted upon it. This can be achieved either by using high strength
material or better cross sections against the applied load. But the most
feasible way to balance the dry mass of chassis with the optimum number of
longitudinal and lateral members. The chassis must be constructed of steel
tubing with minimum dimensional and strength requirements dictated by
ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS).

2.2 History

Racing Go Karts have evolved over the past 50 years to become one of the
most competitive forms of motor racing in united states. Kart Racing has
been a stepping stone for many drivers working their way up the
professional ladder in NASCAR, FORMULA 1 and the INDY RACING
LEAGUE. Drivers like TONY STEWART, DANICA PATRICK, MICHAEL
SCHUMACHER and SARAH the late 1950’s an American company modified
a two stroke chain saw motor and the McCulloch MC-10 became the first
motor manufactured specially for go kart racing.

2.3 Design Objectives

Design objectives of chassis are:

 Provide full protection of the driver, by obtaining required strength

and torsional rigidity, while reducing weight through diligent tubing
selection
 8

 Design for manufacturability, as well as cost reduction, to ensure both

material and manufacturing costs are competitive with other Go
Karts.
 Improve driver comfort by providing more lateral space in the driver
compartment
 Maintain ease of serviceability by ensuring that chassis members do
not interfere with other subsystems
 Deciding the cost efficiency of such in terms of large scale
manufacturing.
 Calculation of stresses acting on the chassis of the vehicle under
different loading conditions.
 The product can prove to be very efficient in all the aspects such as
cost, drivability, maintenance, easy usage, safety etc.
9

Chapter 3

OBJECTIVE &
PROBLEM
 10

Chapter 3 OBJECTIVE & PROBLEM

The frame is designed to meet the technical requirement 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. The number one priority in the chassis design was driver safety.
Byte competition rules and Finite Element Analysis(FEA), the design
assured. The purpose of the body is to prevent debris from entering the
vehicle, with the intent of protecting the driver and the vehicle’s
components. The seat was designed to support the driver comfortably and
safely while they are operating the vehicle. This project is striving to produce
a low cost go-kart chassis by designing with CAD and by using locally
available fibreglass. The feasibility of the go-kart design is to be examined
through FEA package. 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. The
chassis frame is the central and supporting part of the whole kart. It must
be sufficiently resistant to be able to absorb the charges produced when the
kart is in motion. Steel tubular construction with a cylindrical section is
allowed. All the chassis main parts must be solidly attached to one another
or to the chassis frame. A rigid construction is necessary, no articulations
(Mobil in 1, 2 or 3 axes). Articulated connections are only authorized for the
conventional support of the steering knuckle and for steering. Any other
device with the function of articulation in 1, 2 or 3 axes is forbidden. Any
hydraulic or pneumatic absorbing device against oscillations is forbidden.
No part may project beyond the quadrilateral formed by the front fairing, the
rear wheel protection and the wheels.

The steering system is designed to withstand the stress of safely

manoeuvring the vehicle through any type of possible condition at the time
of driving. The purpose of the steering system is to provide directional
control of the vehicle with minimum input. The main goal for steering radius
of 4m or less and have 100% Ackerman steering. Steering system must be
controlled by a steering wheel which a continuous rim not incorporating any
reflex angles in its basic shape. The upper and lower 1/3 of the
 11

circumference may be straight or of a different radius to the rest of the

wheel. The rim must be manufactured with a metallic structure made of
steel or aluminium. Any device mounted on the steering wheel must not
protrude by more than 20 mm from the plane forward of the steering wheel
and must not have sharp edges. Flexible steering controls by cable or chain
are forbidden. All parts of the steering must have a method of attachment
offering maximum safety (split pins, self-locking nuts or burred bolts). The
steering column must have a minimum diameter of 18 mm and a minimum
wall thickness of 1.8 mm. It must be mounted with a safety clip system for
the lower bearing restraint nut. The steering column must be made of steel.

The vehicle must be equipped with a braking system that is operated by a

single control. Rear braking is only allowed. “Brake-by-wire” systems are
prohibited. Braking fluid should be preferably DOT-3 or DOT-5. The brake
control [the link between the pedal and the pump(s)] must be doubled (if a
cable is used, it must have a minimum Ø of 1.8 mm and be blocked with a
cable clip of the flat clip type). Brake discs must be mandatorily being made
from steel, stainless steel or cast iron. Everybody can use tires of their
choice. The rims must be fitted with pneumatic tires (with or without tubes).
The number of wheels is set at four. Only the tires may come in contact with
the ground when the Driver is on board. By set of tires is meant 2 front tires
and 2 rear tires. The simultaneous use of tires of different makes or of
“slick” and “wet weather” tires on a kart can be used. The attachment of the
wheels to the axles must incorporate a safety locking system (such as split
pins or self-locking nuts, etc.). The use of rims complying with the technical
drawing appended is compulsory.
12

Chapter 4

METHODOLOGY
 13

4.1 DESIGN CALCULATION

4.1.3 steering

The steering wheel is mechanically connected to the wheels, they can

use any mechanical system, steering System is mechanical linkage design.

The Steering System Provides Control Over Direction of travel, good

manoeuvrability, and smooth recovery from turns and minimum
transmission of road shocks. In Mechanical systems there is a direct link
between to the front wheels

Calculations

the Ackerman condition is expressed as

cotɵ0 – cot ɵi = c/b

where,

ɵ0 = outer steering angle

ɵi = inner steering angle

c = distance between kingpin

b= wheel base

assuming ɵi = 35°

b= 1270mm

c = 762mm

from the above equation

cotɵ0 - cotɵi = c/b

cot ɵ0 = (762/1270) + (1/tan (35°)

cotɵ0 = 2.028°

ɵ0 = 28.23°

now The Ackerman angle (α)

 14

tan(α) = kingpin distance/2 x wheel base

α = tan-1 (762/2 x 1270)

α = 16.67°

Turning Radius (R)

R = (b/sin ɵ)- length of stub axle

R = (1270/sin 31.26°)- 101.6

R= 2.34 m

Fig 4. Steering System Design

4.2. 3D MODELLING

4.2.3 Steering

The design of the steering was modelled using SOLIDWORKS 2018 software

Handling of the steering should be easy and compactable as possible.

The steering wheel is mechanically connected to the wheels, they can

use any mechanical system, steering System is mechanical linkage design.

The Steering System Provides Control Over Direction of travel, good

manoeuvrability, and smooth recovery from turns and minimum
transmission of road shocks. In Mechanical systems there is a direct link
between to the front wheels.
 15

The steering mechanism used here is the mechanical linkages that is

connected to the steering wheel through an adjustable tube that can be
adjusted at three different heights.

Fig:10. Steering System Design

4.3 Analysis

4.3.1 Chassis

The design made in SOLIDWORKS is tested in the same software

using stimulation.

The results in the stimulation were not satisfactory so changes in design

were made and more cross members are added to support and strengthen
the structure.

Fig:14.Applied Front Load : 8000N Fig:15. Applied Rear Load: 4000N

 16

Fig:16.Applied Side Load: 6000N

4.4 FABRICATION

4.4.4 Steering

The steering system for the vehicle has to be designed to provide

maximum control of the vehicle. Simplicity and safety were the main design
specifications for the vehicle’s steering system. The main goal for steering is
to have steering radius of 4m or less. Along with controlling the vehicle, the
steering system has to provide good ergonomics and be easy to operate.
After researching multiple steering systems, the four bar steering type was
selected which provides easy operation, less weight, requires low
maintenance, provides excellent feedback and is cost effective. Ackerman
steering mechanism has been selected for steering system because it does
not slip during the turning of tires and it reduces the steering efforts. The
positive 3-degree caster is given for self-cantering of the kart. Mechanical
steering linkage system has been used to make steering simple to
manufacture, decrease the steering effort and the amount of steering wheel
travel and increase the steering responsiveness.
 17

Fig 34. Steering System Design

Fig 35. Adjustable Steering Column

Advantages

 The steering system is set such that the driver feels comfortable
with the steering wheel positioning.
 This steering system is easy to construct.
 Less maintenance is required.
 This is one of the cheapest and best steering systems suitable
for go karts.
 It is easy to operate.
 The design includes adjustable tubes which can be used for
varying height of steering wheel according to driver’s comfort.
 18

Disadvantages

 It has a small amount of vibrations when the vehicle starts.

 It takes more effort for turning the steering wheel while in stand
still position

4.6 Assembly Of Mechanical Components

4.6.3 Steering

Settings provided on the knuckle.  Ackerman setting as per

calculated.  Parallel steering Tie rods will be pivoted on single point on
knuckle. As per Ackerman geometry, as the wheels will turn at different
angles, the front inside being greater the steering response will be quite
fast. During high speed cornering the outer tire will be shifted on the outer
wheel, where in parallel steering would be effective.

Fig:51. Assembly of steering

 19

Fig:52. welding of steering.

4.8 Final Project Model

4.8.3 Steering

Fig:63. Steering System

20

CHAPTER 5

RESULT
 21

5.1 Results and Discussion:

The frame members joining at right angles are mitred at an angle of 450.
The diagonal ones are mitred to the requirement of the joint being made.
Welding is done on all the members and every joint should be a complete
one that is, no holes should be left unfilled in the frame. This ensures that
the strength of the frame is not compromised.

The rear axle is mounted to the frame through bearings on a bearing carrier
bolted to a plate. The plate is welded on to the frame this is done to avoid
any possible weakening of the frame. Hubs carrying both the sprocket and
the rotor are mounted onto it. The hubs are anchored on to the shaft using
bolts with the help of a key to enhance the torque transmission.

A hub was mounted on the front axle to carry the wheel. To enhance the
safety in case the nut loosens a jam nut was added to make sure the hub
was securely in place.

These wheels were chosen because of their availability and the clearance
they could offer thus enhancing the stability of our kart. The wheels are
threaded this allow the car to be used on an all-weather road.

The motor which is placed strategically behind the driver’s seat is guarded
from direct contact with a metallic plate insulated from the side facing the
motor to eliminate injuries that can happen due to exposure to moving
parts and to guard against high temperatures. It is held onto the frame by a
casing that is bolted onto a plate. The plate is bolted onto the frame.

Wires used in the wiring to connect the motor to the accelerator and the
motor controller are insulated. This reduces the chances of the operator
coming into contact with live wires.

The four lead acid batteries are kept in a container that is a non-conductor.
The container is fixed onto the frame welded onto the frame. This ensures
that the operators or the driver is not exposed to the corrosive substance
and prevent a possible exposure to high voltages.

The braking cable is fixed in such a way to minimize the number of

corners or the angle of bend. This is important to minimize stress
concentrations and wear on the cable and also ensure that the cable
transmits the required braking force.
22

Chapter 6

Conclusion
 23

6.1 Conclusion: Static analysis using finite element method was

successfully carried out to determine maximum deflection and its
location on chassis structure. The results of analysis revealed that the
location of maximum deflection agrees well with theoretical maximum
location of simple beam. This study found out that there is discrepancy
between the theoretical (2-D) and numerical (3-D SOLIDWORKS) results.

There are a variety of ways in which this design may be improved that were
not implemented in this project. Some of the improvements include the use
of a closed body using light materials like carbon fibres or fibre glasses. The
chassis or frame could also be made of different materials. The lower part
taking on steel then the upper can either be made using the advanced
composites or aluminium alloys.

A second improvement could be to use longer lasting alkaline batteries as

opposed to the lead acid batteries. The seat can be made adjustable to
accommodate both younger and adults comfortably.

6.2 Future Scope: As of now, Go-Karts are only used for recreational
purposes in India. But there are Automobile manufactures which
produce high performance Go-Karts which are street legal. For example,
Ariel Atom manufactured by Ariel Motor Company and KTM X-Bow
manufactured by KTM. So in future, Go-Karts can be used as a people’s
mover, which are safer and gives high comfort.