Structural Analysis of Go-kart Chassis using different materials to find the suitable material for the given model

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 01 | Jan 2023 www.irjet.net p-ISSN: 2395-0072
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Structural Analysis of Go-kart Chassis using different materials to find
the suitable material for the given model
Atharva Kondhare, Sandesh Pawar, Anisa Diwan
Atharva Kondhare, Dept. of Mechanical Engineering, VIIT College, Maharashtra, India
Sandesh Pawar, Dept. of Mechanical Engineering, VIIT College, Maharashtra, India
Anisa Diwan, Dept. of Mechanical Engineering, VIIT College, Maharashtra, India
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Abstract - In the present work, the chassis of the go-kart is
designed and simulated for different impact positions such as
front impact, side impact, & rear impact testsforfourdifferent
materials. Initially, the chassis was designed using 3D CAD
software and then simulations is carried out in ANSYS
Workbench. The work shows the failure criteria based on von-
mises stress for selected materials. The work aims to get the
perfect materials for chassis that can withstand the range of
force that the drivers experience while driving low-ground
clearance go-karts. The reason to carry out a range of force
analysis is that the kart should have maximum value for the
factor of safety. The same range of a force is carried out on all
the impact positions. For the current analysis, the strength of
materials and structural rigidity are the main consideration.
Key Words: Chassis; Go-Kart; CAD Modelling; AISI:
Simulation.
1. INTRODUCTION
The Chassis is the metallic frame or Rigid Structure onto
which all other components of a body are fixed. The work of
the chassis is to carry the load of the vehicle and its
passenger and resist the torque and thrust loads from the
engine and gearbox, as well as those from stopping and
accelerating, surviving the centrifugal force when turning.
The chassis' construction is made up of thick tubing and
tubes with different cross sections that supportthedifferent
vehicle parts and protect the driver [1]. This work’s
discussion and result are based on the design and structural
analysis of kart chassis under different loading conditions.
The go-kart has an extremely low ground clearance
compared to other cars and is specifically made for racing.
The engine, wheels, steering, tires, axle, and chassis are the
typical components of a go-kart. Go-karts cannot be
equipped with suspensions because of their low ground
clearance. [2].
Now, computer-aided engineering tools are used to design
land vehicles [3]. Computer dynamic simulation techniques
are frequently used to examine how those vehicles behave
under various input situations [4]. Finite element analysisis
used for the structural analysis of different types of vehicles.
The FEA is used to calculate the generated stresses and
strains from different input scenariosthathave beenapplied
as boundary conditions. [5]. Internal and external loads are
acting on a Body. The internal load is broughtonbythemass
of the vehicle and payloads, while the external loads are
brought on by the wheel-ground interface, moving through
the suspension mechanism and its elastic components, and
from the aerodynamic field surrounding the car body [1].
2. Methodology
1. Material Selection
The concerns of the manufacturer regarding laws and
regulations, as well as some customer demands, determine
an automotive chassis. Most producers favor affordable,
secure, lightweight, and reusable materials. The primary
considerations for choosing a material, particularly for the
body, involve a wide range of properties like resilience,
production effectiveness, and
thermal, chemical, or mechanical resistance. Mainly two
materials are considered while constructing chassis & they
are steel and aluminum. Aluminum is corrosion-resistant,
however, due to its low flexibility modulus, it is not able to
replace steel parts. As a result, such components must be
redesigned to adopt the same mechanical strength. It is
utilized as wheels, brackets, brake parts, suspension parts,
steering parts, and instrumentpanelsinchassisapplications.
Steel is the material of choice for producersbecauseithasall
the necessary qualities. Steel is now stronger, lighter, and
more rigid than it was in the past thanks to advancements
made in the steel industry. Steel's inherent capacity to
absorb the impact energy created in a crash makes it ideal
for body structures. So, for better material Selection in Go-
kart chassis, we take AISI Steel Standards. The selected
materials are AISI 1018, AISI 1026,AISI4130,andAISI1020.
The Table 1. Shows mechanical properties of
selected materials.
properties Materials
AISI
1080
AISI
1026
AISI
4130
AISI
1020
Young's Modulus
(GPa)
200 200 210 205
Poisson’s Ratio 0.29 0.3 0.3 0.29

Yield Tensile
Strength(MPa)
370 415 435 297.79
Density (Kg/m3) 7850 7858 7850 7870
Table -1: Properties of selected materials
2. Modelling
The 3D model of the chassis is designed with the help of
Solidworks. SolidWorks is a softwaremainlyusedtodevelop
mechatronics systems from beginning to end. Using the 3d
sketch option initially chassis sketch is formedinXY,YZ& XZ
planes. Then using the weldments method hollow pipes are
created on the sketch. The hollow pipe is ISO 26.9 x 3.2
diameter. The chassis is formed by using hollow pipes as
they result in less weight as compared to the solid pipe
For CAD Modelling
Scale:
Chassis Length= 2m
Chassis Width= 0.66m
Diameter Of pipe= ISO 26.9 * 3.2
Figure 1.1: Top view Sketch with dimensions (mm)
Figure 1.2: Side View
SolidWorks makes it simple to create a pipe structure using
the weldment method or option Feature. Solid Works also
Offers a 3d sketching method Therefore it is easy to sketch
the chassis in a three-dimensional way
Figure 1.3: Chassis top view
Figure 1.4: Chassis isometric View
Figure 1.5: Chassis side View
3. Fine Element Analysis (FEA)
The chassis behavior under actual physical force is
understood using finite element analysis (FEA) [6]. To
ensure safety when operating the go-kart, the chassis'
structure must be strong and able to bear the forces applied
to it. Static analysis is necessary to ensure that the chassis
complied with the specifications [1]. For Finite Element
Analysis, Ansys Software is used.
2.3.1.Meshing
Meshing helps to divide a complicated object into clearly
defined cells where the general equation can be assigned so

that the solver can easily simulate physical behavior. Highly
accurate simulations are made possible by the 3D CAD
model's increased accuracy and processingtimeasthemesh
becomes more precise [6].
Figure 2.1: Go-Kart Chassis After meshing
Figure 2.2: Close look at the quality of the chassis
The geometry used for mesh is tetrahedral and the element
size is kept to 3mm. Total nodes are 2,20,000 and elements
are 8,04,100 physics preference is kept CFD, & Solver
Preference is Fluent And Element Order is Linear.
2.3.2.Boundary Conditions
Three conditions were imposeddependingonthefront,side,
and Rear impact tests. For the Front impact test, the rear
section was fixed and a force was applied to the front
section, as shown in Figure 3.1. For the side impact test, One
side of the chassis is fixed, and on the other side, the force
was applied, as shown in figure 3.2. And for the Rear side
impact test the front section was fixed,andforcewasapplied
to the rear section of the chassis, as shown in figure 3.3
Figure 3.1: Condition for Front Impact test
Figure3.2: Condition for Side Impact Test
Figure 3.3: Condition for rear impact test
2.3.3.Solution
Analysis of all selected materials was performed using
ANSYS to determine thefactorofsafetyanddeformation that
the built chassis experiences when a load is applied to it in
front static impact and Side static impact [6].
Front Impact Test
Let us consider for the front analysis test, that the maximum
weight of the driver is 100 kg, and the maximum weight of
the Go-Kart is considered 100 kg; therefore, Assuming the
vehicle is struck by the applied load for a brief period at a
velocity of 70 km/hr during the front section of the chassis,
the go kart's weight with the operator is assumed to be 200
kg. Analysis of the impact load's impact varies depending on

the driver's perception of safety and is done for a range
where loads are measured at 4g, 6g, and 8g.
Figure 5.1: maximum deflection in chassis for front
Figure 5.2: Maximum Von-mises stress for front impact
Side Impact Test
Let us consider for the Side Analysis test, that the maximum
weight of the driver is 100 kg, and the maximum weight of
the go-Kart is considered 100 kilograms; therefore, the total
weight of the go-kart with the Operator is taken as 200 kg.
assuming that the vehicle is briefly hit by the applied load
while traveling at 70 km/hr in the selected section of the
chassis. Analysis of the impact load's effectvariesdepending
on the driver's perception of safety and is done for a range
where loads are measured at 4g and 6g.
Figure 5.3: maximum deflection in chassis for side impact
Figure 5.4: maximum deflection in chassis for side impact
Figure 5.5: Max Von-mises stress for side impact
Rear Impact Test
Let us consider for the rear analysis test, that the maximum
weight of the driver is 100 kilograms, and the greatest
possible weight of the Go-Kart is considered 100 kilograms;
therefore, the total weight of the go-kart with theoperator is
taken as 200 kg. assuming that the load strikes the car at the
velocity of 70 km/hr in the selected section of the chassisfor
a brief period. Analysis of the impact load's impact varies
depending on the driver's perception of safety and is done
for a range where loads are measured at 4g, 6g, and 8g
Figure 5.6: Maximum deflection in chassis for rear impact

Figure 5.7: Maximum Von-mises stress for rear impact
3. Result and Discussions
For results, the calculations are done by using the F.O.S
formula. If the factor of safety is greater than or equal toone,
then this design is said to be safe. The loads used in impact
tests, the maximum deflection, and the induced Von Mise
stress is displayed in the tables
For safe design
F.O.S ≥ 1
Front Impact Test AISI 1080
Load
Criterion
Force
(N)
Max stress
(MPa)
Deformation
(mm)
Yield strength
(MPa)
FOS Remark
4g 7848 186.99 14.664
370
1.97 Safe design
6g 11772 280.49 21.997 1.31 Safe design
8g 15696 373.98 29.329 0.98 Failure
Table 1. Front Impact Test AISI 1080
Side Impact Test AISI 1080
Load
Criterion
Force(N)
Max stress
(MPa)
Deformation
(mm)
Yield
FOS Remark
strength
(MPa)
4g 7848 94.569 0.83722
370
3.91 Safe design
6g 11772 141.85 1.2558 2.6 Safe design
Table 2. Side Impact Test AISI 1080
Rear Impact Test AISI 1080
Load
Criterion Force(N)
Max stress
(MPa)
Deformation
(mm)
Yield strength
(MPa) FOS Remark
4g 7848 225.06 3.1652
370
1.64 Safe design
6g 11772 337.6 4.7477 1.09 Safe design
8g 15696 450.13 6.3303 0.82 Failure
Table 3. Rear Impact Test AISI 1080

Load
Criterion
Force(N)
Max stress
(MPa)
Deformation(mm)
Yield strength
(MPa)
FOS Remark
4g 7848 214.45 12.316
415
1.93 Safe design
6g 11772 321.68 18.474 1.29 Safe design
8g 15696 428.9 24.632 0.96 Failure
Load
Criterion Force(N)
Max stress
(MPa) Deformation(mm)
Yield strength
(MPa) FOS Remark
4g 7848 109.26 0.98472
370
3.38 Safe design
6g 11772 163.89 1.4771 2.25 Safe design
Load
Criterion Force(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 236.4 3.1717
415
1.75 Safe design
6g 11772 354.59 4.7576 1.17 Safe design
8g 15696 472.79 6.3435 0.87 Failure
Load
Criterion Force(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 199.22 10.063
415
2.08 Safe design
6g 11772 298.83 15.095 1.38 Safe design
8g 15696 398.45 20.126 1.04 Safe design
Load
Criterion
Force
(N)
Max stress
(MPa)
Deformation
(mm)
Yield strength
(MPa) FOS Remark
4g 7848 112.17 0.93769
415
3.69 Safe design
6g 11772 168.25 1.4065 2.46 Safe design

Load
Criterion
Force
(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 229.58 3.021
435
1.89 Safe design
6g 11772 344.37 4.5315 1.26 Safe design
8g 15696 459.16 6.0419 0.94 Failure
Load
Criterion Force(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 199.07 11.142
297.79
1.49 Safe design
6g 11772 298.61 16.713 0.99 Failure
8g 15696 398.15 22.284 0.74 Failure
Load
Criterion Force(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 112.55 0.95971
297.79
2.64 Safe design
6g 11772 168.82 1.4396 1.76 Safe design
Load
Criterion Force(N)
Max stress
Yield strength
(MPa) FOS Remark
4g 7848 236.85 3.0915
297.79
1.25 Safe design
6g 11772 355.27 4.6373 0.83 Failure
8g 15696 473.7 6.183 0.62 Failure
4. CONCLUSIONS
1. According to the findings of this study, for front impact
tests, AISI 4130 material performs well under 4 g, 6 g,
and 8 g loads, with the highest factor of safety when
compared to the selected material.
2. In the side impact test, all selected materials performed
well under 4 and 6 g loads, but AISI 1080 is safer than
other materials.
3. For the rear impact test, again, AISI 4130 is a safer
material.
4. From the overall result, AISI 4130 is the most effective
material among the selected materials under 4 g, 6 g,
and 8 g loads.

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BIOGRAPHIES
SANDESH PAWAR
Dept. of Mechanical Engineering, VIIT
College, Maharashtra, India.
ANISA DIWAN
Dept. of Mechanical Engineering,
VIIT College, Maharashtra, India.
Atharva Kondhare
Dept. of Mechanical Engineering, VIIT
College, Maharashtra, India

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