DESIGN AND ANALYSIS OF
CHASSIS OF
A MODERNIZED ELECTRIC
GO-KART
PAPER ID:- IJSRSET_103
Our team
SUVIKRAM
PRADHAN
ANSHUMAN
NAYAK
AVINASH
SHARMA
DEEPANKAR
MAHATO
ASHESH
NAYAK
Table of contents
01.
ABSTRACT& KEYWORD
03.
LITERATURE SURVEY &
BODY OF PAPER
02.
INTRODUCTION
04.
MATERIAL SELECTION &
ANALYSIS
05.
06.
RESULT &
CONCLUSION
REFERENCE
01.
ABSTRACT
ABSTRACT
As we are in the era of the technological advancement all the technologies
including various industries have come to a greater position. From big bang to
black holes the humanity has come a great way along. at ancient times we have
the automobiles which run with either human power or with the power of animals
(ox).Now we have entered the era of energy and its storage for use and almost
80-85% of automobiles present in market are IC ENGINE powered but as the
pollution is concerned we are entering the age of the new concerned automobile
vehicles {nonconventional automobiles are those which run on various nonconventional fuels}.So it is one of the major concern that how much the electric
vehicles have the advantage over the conventional IC engine or wobblers engine
;stirling engine; boxers ; v engines ; rotary and solenoid engines . Thus this paper
is presented for the topic of “DESIGN AND FABRICATION OF E-GOKART” that is one
of the miracles of engineering. Here the design CAD model is made using DSS
CATIA and analysis was done using ANSYS software’s.
02.
INTRODUCTION
INTRODUCTION
First of all, what does the term automobile mean! As per human
psychology and understanding AUTOMOBILE is a machine that is
used has transportation of goods and services it comes into
pictures years back. To when the 1st steam engine comes to be
used and the 1st industrial revolution takes place and then the
era of energy began and from that there is advancement and a
number. of engines came into picture. After the steam engines
petrol or SI engines comes into use which uses petrol as the
working fluid and then used by Ford as well as British automotive
and then through one more advancement by the Greatest
inventor Rudolf diesel the diesel engines come to market whose
working is similar to the petrol engines but are more efficient. On
the other hand, they are much pollution seeking. Hence in the
below diagram it is clearly shown the disadvantages of petrol
and diesel engines.
 These are the thermodynamic plots of both engines and
now it is shown from (4-1) process the exhaust is taking place
and a large amount of energy developed by the engine is
thrown outside the engine and its efficiency reduces. On this
disadvantage a newer engine “Stirling engine" comes to
picture which works either on compressed air or on steam
But the disadvantage of this engine is it that it is not capable
of producing that tremendous amount of required power as
done by other 2 engines.
 So as per requirement and the quotation “NECESSITY/
REQUIREMENT, IS THE MOTHER OF ALL INVENTION" we are now
using various non-conventional sources of energy such as
bio fuels; electric power. Now the electric powered vehicle
comes in to the picture which are powered by electricity and
propelled by electric BLDC Motors and is less pollution
seeking as compared to conventional.
03.
LITERATURE
REVIEW
&
BODY OF THE
PAPER
LITERATURE REVIEW
 WEAR BEHAVIOUR OF GREY CAST IRON WITH THE PRESENCE OF COPPER ADDITION, BY
SHABAN ABDOU, AHMED ELKASEER, HANAN KOUTA AND JABER ABU QUDEIRI, ON
2018.
Here it is clearly mentioned about an investigation carried out through an experiment for
testing the wear resistance of grey cast iron sample with addition of different marterials of
copper ranging from 0.00 to 3.15%. In the experimental results it is mentioned about the
increase in weight loss is directly proportional to the time of wear, rotational speed and
applied mixture. It is mentioned that the quantification of cast iron with some amount of added
copper was done to identify the wear losses. It was also found that on increase of wt.% in
copper from 0.00 to 3.15 wt.% resulted in 30%⁰ (approx.) material loss. Here the material
selection was done by considering the most exploited material (Grey cast iron) which is
common and its proportions where 2.5-4.2 wt.% C, 1.0-3.0 Wt...℅SI, 0.15-1.0Wt% Mn, 0.02 -0.25
wt.% S and 0.02-1.0 wt.% P with the addition of some small impurities in order for increasing the
strength and the production % of casting becomes in Uniramous because of this Factor. As
they have a greater wear resistance and their mechanical. Strength when combined with the
vibration damping helps them for making their selection suitable for a greater wide range of
automotive components.
 ALUMINIUM IN INNOVATIVE LIGHT-WEIGHT CAR DESIGN BY JURGEN HIRSEH ON MAY 1,
2011.
Here it is mentioned about the concepts of innovative car concepts for solving the conflict of
public and private mobility as well as improving the environmental efficiency and co2
emission reduction. Here it is mentioned about the usage of Aluminum as because of its light
weighting factor and by the method of weight savings 50% reduction of weight can be
achieved and also results in stability as well. Weight savings can be done by the use of Full
aluminum bodies up to 70 to 140 kg (i.e., 30- 40%) which results depends upon the size of car,
as because of growing competition, the light weight factor becomes more important for
smaller in case of mass-produced cars savings can be done by the use of Full aluminum
bodies up to 70 to 140 kg. (i.e., 30-40%) which results depends upon the size of car. As because
of growing competition, the light weight factor becomes more important for smaller and in
case of mass-produced cars. And various car manufacturers have learnt the usage of
aluminum like the new high steel graders. Mechanism casting and steel and various FRPS are
also been tested and developed by the leading OEMS the results concluded that aluminum
wins in race with high recycle rates in case of cars and the fact is only 5% original energy
consumption is only required. For the hang on parts like hood, doors and precipitation,
hardening 6000 series alloys are used because of its excellent surface quality.
BODY OF PAPER
 Safety of rider
 Optimum Fuel consumption
 Driving Comfort
The primary objective of the chassis is to produce a three-D protected area round the
driver that may keep the motive force safe. Its secondary motive is to produce reliable
mounting locations for elements is appealing, low in value, and low in weight. These
objectives were met by selecting a chassis material that has sensible strength and
conjointly weighs less giving it a bonus in weight reduction. A low price chassis was
provided through material choice and incorporating a lot of continuous members with
bends instead of a group of members welded along to scale back producing prices.
The modeling of the chassis structure is completed by Catia v-5 package. This style is
checked by Finite element Analysis. We’ve got centered on each purpose of chassis to
boost the performance of vehicle while no failure of chassis.
04.
MATERIAL
SELECTION
&
ANALYSIS
MATERIAL SELECTION
There are various materials that can
be selected for the chassis but the
major issue for the material selection
is that it should be meeting all the
required properties for the chassis so
that it should take all the various
loads while no deformation will be
taking place on the other hand it
should also be light weight. Below
table shows the chemical composition
of the materials:-
FINITE ELEMENT ANALYSIS (FEA)
Finite part analysis (FEA) could be a computerized methodology for predicting however a
product reacts to real-world forces, vibration, and alternative physical effects. Finite part
analysis shows whether or not a product can break, wear out, or work the method it
absolutely was designed. Here we have a tendency to divide the chassis into small sizes
referred to as part and collective components on the model kind a mesh. The computer
analyses the weather and shows a collective result. The program solves problem by the
computational methodology provided. The structure of chassis was finalized so FEA was
performed there on. It’s tested whether or not the chassis are ready to stand up to
torsion, impact. The analysis was exhibited using ANSYS R16 software.
MESHING
Auto meshing has been taken out in ANSYS R16 software. Following information has been
found when meshing of chassis
 No. of Nodes = 46790
 No. of parts = 16181
CAE ANALYSIS {STATIC STRUCTURAL AND
TRANSIENT THERMAL} OF CHASSIS
GRAY CAST
IRON
ALUMINIUM
ALLOY
STAINLESS
STEEL
STRUCTURAL
STEEL
TITANIUM
ALLOY
CAST IRON
ALUMINIUM
ALLOY
STAINLESS
STEEL
TITANIUM
ALLOY
05.
RESULT
&
CONCLUSION
RESULTS
From the above experiments we have formulated the CAD model of the CHASSIS
that is used in the electric go-karts and have done the analysis of it using
ANSYS and SOLIDWORKS software and got various results.
S.NO
MATERIALS
DIRECTIONAL HEAT
FLUX
TOTAL HEAT FLUX
TOTAL
DEFROMATION
STRAIN ENERGY
1.
CAST IRON
MIN=-2.2147e-7 W/m2
MIN=8.2363e-11 W/m2
MIN=8.9874 m
MIN=2.7535e-10 J
MAX=2.1893e-7 W/m2
MAX=3.3424e-7 W/m2
MAX=9.0715 m
MAX=0.066968 J
MIN=--8.1491e-8 W/m2
MIN=1.4204e-7 W/m2
MIN=5.1223 m
MIN=1.581e-10 J
MAX=8.0407e-8 W/m2
MAX=1.1909e-7 W/m2
MAX=5.1703 m
MAX=0.038551 J
MIN=--6.8006-7 W/m2
MIN=1.1223e-10 W/m2
MIN=13.924 m
MIN=4.3172e-10 J
MAX=6.314e-7 W/m2
MAX=9.4927e-7 W/m2
MAX=14.055 m
MAX=0.105481 J
MIN=--9.4935e-8 W/m2
MIN=2.5239e-11 W/m2
MIN=10.298 m
MIN=3.2124e-10 J
MAX=9.2987e-8 W/m2
MAX=1.4638e-7 W/m2
MAX=10.394 m
MAX=0.078777 J
2.
3.
4.
STAINLESS STEEL
ALUMINIUM ALLOY
TITANIUM ALLOY
CONCLUSION
 The steady state thermal and static structural analysis as well as the dynamic /
impact analysis of the vehicle chassis and frame is recurrent in an automobile that
has been performed in conjunction with the theoretical style. The most common
materials for the chassis are shown above and through the static and dynamics
analysis it is clear that CAST IRON is the most preferable material for usage as a
chassis because it can withstand more forces either we can say the major stress
more effectively and efficiently without any breakage evidence as compared to
other materials. A look towards the dynamic analysis also shows that if same
amount of impact load will be applied to the chassis made up of different materials
than the most deformed chassis will be of aluminum followed by other materials.
 A look towards the dynamic analysis also shows that if same amount of impact load
will be applied to the chassis made up of different materials than the most
deformed chassis will be of aluminum followed by other materials.
06.
REFERENCE
REFERENCE
 Wear behaviour of grey cast iron with the presence of copper addition, By




Shaban Abdou, Ahmed Elkaseer, Hanan kouta and Jaber Abu Qudeiri, ON
2018.
Structural Analysis of a Heavy Vehicle chassis is made of different Alloys
by Different cross Section, BY Abhishek Sharma, Mr Pramod Kumar, Abdul
Jabbar, Mohammad Mamean Khan, and ON 6 June2014.
Aluminium in Innovative Light-Weight car design by Jurgen Hirseh on May 1,
2011. 4
High strength aluminium alloys in car manufacturing, BY M Tisza and lukaes.
Corrosion Aspects Regarding the use of Martensitic Stainless Steels in
Automotive chassis Parts, BV Fiona Ruel, Pierre Santacreu, G. Badinicu, ON
April 2015.