GOKART PROJECT
- 1. SRI INDU COLLEGE OF ENGINEERING AND TECHNOLOGY (HYDERABAD).
- 2. Parameter Value vehicle length 70 inch vehicle width 55 inch Wheel base 45 inch Wheel track 35 inch Roll cage material AISI 1018 Tube dimensions 1 inch OD 3 mm thick Roll cage mass 12 kg Total mass 170 kg Ground clearance 1 inch Battery 12 V Max speed 65 kmph Brake Hydraulic disc brake Steering Pitman arm Tyre 10*4.5*5 (front) 11*7.1*5 (rear) VEHICLE SPECIFIATIONS
- 3. Material Density (gm/cc) Yield strength (Mpa) Outer diameter (mm) Thickness (mm) Bending strength ( N-m) Bending stiffness (N/mm) Hardness (BHN) Tensile Strength (Mpa) Elastic Modulus (Mpa) Poisson' s ratio AISI 1018 7.87 370 25.4 3 387.38 134.78 126 440 205 0.29 MATERIAL SELECTION FOR CHASSIS Length 59 inch Width 29 inch weight 12 kg DESIGN METHODOLOGY Main Dimensions
- 4. FINITE ELEMENT ANALYSIS FRONT IMPACT REAR IMPACT Total Deformation(max) = 0.67 mm Load applied = 7.5 G Total Deformation(max) = 0.13 mm Load applied = 7.5 G Equivalent Stress(max) = 285.6 Mpa Load applied = 7.5 G Equivalent Stress(max) = 138.9 Mpa Load applied = 7.5 G
- 5. SIDE IMPACT TORSION Case Total applied Force (G) Max Stress (Mpa) FOS Max Deformation(mm) Front impact 7.5 285.65 1.20 0.67 Rear impact 7.5 138.90 2.80 0.13 Side impact 5.0 662.72 1.07 1.30 Torsion 43 N-m 26.17 1.68 0.022
- 6. ERGONOMICS AND SAFETY MAINTAINED • SPACIOUS COCKPIT. • INTEGRATION OF 95 PERCENTILE MALE IN COMFORTABLE POSITION. • CLEAR LINE OF SIGHT. • ALL THE PARTS ARE WITHIN REACH TO ACCESS. • COMPLETE DRIVER’S KIT. INNOVATION 1. THINKING TO HAVE A BRAKE FLUID SENSOR OVER MASTER CYLINDER TO KNOW THE LEAKAGES. 2. ENERGY GENERATION USING EXHAUST GASES
- 7. STEERING Parameters Values Wheel track 35 inch Wheel base 45 inch Mechanism Ackerman steering (pitman arm) Tie rod length 13.7 inch Inner turning radius 1.6 m Outer turning radius 2.67 m Max. inner turning angle 34.89o Max. outer turning angle 24.530 Max Deformation = 0.295mm
- 8. BRAKING SYSTEMOuter dia of disc 200 mm Disc thickness 6 mm Tyre radius 127 mm &139.7 mm Pedal ratio 6 : 1 TMC piston dia 19 mm Caliper piston dia 29 mm Driver effort 100 N Brake force on TMC 600 N Pressure inside TMC 4.23 N/mm2 Caliper force 2795.56 N Frictional force(disc and pad) 1677.36 N Braking torque 143.48 N-m Deceleration 25.36 m/sec2 Velocity 40kmph 50kmph 60kmph 70kmph 80kmph Stopping distance(m) 2.43 3.80 5.47 7.45 9.73 Stopping time(sec) 0.44 0.55 0.65 0.74 0.87 COG LOCATION Height of COG 6 inch wheel base 44 inch Dynamic load distribution 60 : 40 Brake fluid DOT 3 Fluid max temp. 205 0 c Max deformation = 0.18mm
- 9. POWERTRAIN ENGINE SPECIFICATIONS (IGNITOR) Displacement : 125cc Max power : 11Bhp@8000rpm Max torque : 11Nm@5000rpm Cooling system : Air cooled Gear box type : manual No.of gears : 5(five) Transmission type : chain drive Clutch : wet multi plate clutch Primary reduction : 3.35 Final reduction : 1.92 GEAR GEAR RATIO’S MAX SPEED (Kmph) ACCELERATION (m/s2) 1 3.076 20.376 6.32 2 1.944 32.364 1.77 3 1.473 42.87 1.15 4 1.19 52.92 0.78 5 1.038 62.92 0.8 Specifications Displacement (cc) Max.power (bhp) Max.torque (N-m) Availability (%) Hero Ignitor 125.0 10.9@8000rpm 11@5000rpm 90 Honda Stunner 124.7 11@8000rpm 11@6500rpm 70 Honda shine 124.7 10.6@7500rpm 10.3@5500rpm 100
- 10. MANUFACTURING AND COST SUMMARY COLLEGE FACILITIES Fabrication Machine Tool Cutting Hand cutter/Power hacksaw Drilling Upright Drill,Radial Drill, Hand Drill Grinding Hand,Bench,Surface Grinders Lathe operations Centre lathes,Capstan lathe Milling Universal milling machine Press fitting Mechanical press Shaping Shaper machine Welding MIG,Arc,Spot,Gas welding machine System Estimated cost Approx. weight Frame and body 10000 25 kg Engine + Transmission 9000 20 kg Brakes 6000 2 kg Wheel 11000 16 kg Steering 3000 5kg Electricals 2000 3 kg Safety Equipment 12000 1 kg Miscellaneou s 5000 10 kg Total 58000 82 kg Pipe bending Mechanical bending machine Special operations CNC machine centre 17% 17% 10% 19% 5% 3% 20% 9% Frame and body Engine+transmission Brakes Wheels Steering Electricals Safety equipments miscellneous OUTSIDE FACILITIES BOM and estimated cost
- 11. PROJECT PLAN
- 12. DESIGN VALIDATION PLAN (DVP) S. No Description Acceptance Criteria Test Method Assignedto 1. Tensile Strength Of Pipe Application Based Tensile Strength Test on UTM Santhosh 2. Weld Strength Test Weld should not crack or break Rapid Hammering Yashwanth 3. Shear Strength of Brackets Application Based Test through Ansys khaja 4. Dimensional Stability Should match with technical specifications sheet prepared Provided tolerance Ravi 5. Engine Mount Durability Not less than 75% energy should be absorbed by mounts Vibration test using accelerometer Anil 6. Alignment of Pipes No variation of calibrated spirit level CombinationSet Gautham 7. Breakcircuit Noleakages Visual inspection Ashok 8. Kill switches Should workproperly Repeated testing Varun 9. Temperature of Firewall Should not exceed 40 C Using Resistance Temperature Detector Varun
- 13. DFMEA
- 14. Transmission Anil - H Vinay Sankeerthan Balu Prakash Santhosh Jayasurya THANK YOU GEAR INFERNO Design Sravan - H Khaja Ashok Pavan Pranaya Braking Mahesh - H Ravi Vikram - VC Shravya Sai Krishna Steering Yashwanth - H Varun - C Maneesh Nikhil – Driver Gautham