GO-KART DESIGN CHALLENGE

PRE FINAL ROUND

Team Super Ignite

GURU NANAK INSTITUTE OF TECHNOLOGY
JNTU-Hyderabad

Team ID : 20152735
TECHNICAL SPECIFICATIONS
Wheelbase 1397mm
Track width 1117.6 mm(Front)
1270 mm (Rear)
Engine Briggs And Stratton 550
Series
3.5 HP@ 3600rpm
7.5 N-m@2600rpm
Steering Geometry Mechanical Linkage
Braking System Hydraulic Disc Brake
200mm
Transmission Unit CVT
Vehicle Length 2032 mm
Centre of Gravity 165mm from ground
Location
Ground Clearance 25.4mm
Mass Of The Vehicle 160kg

1397 mm
1270mm 1117.6 mm
2032 mm
 Front Impact
DESIGN & ANALYSIS
Deceleration 5g
Design Methodology
Specifications
Load 5000N
 Requirements Weight of Chassis 12.79 Kg
Max Stress 171.8
 Design calculations and Analysis Weight of Go-Kart 87.8 Kg /Displacement MPa/1.9mm
 Considerations Total No of members 17
Factor of Safety 2.2
 Testing
Side Impact
 Acceptance
Material Specs Composition % Deceleration 2.75g
Density 7.64 g/cc Carbon 0.23%
Load 3500N
Poisson’s Ratio 0.3 Silicon 1.7%
Yield Strength 310 MPa Phosphorus 0.035% Max stress 121.1Mpa/
/Displacement 1.14mm
Ultimate Strength 415 MPa Sulphur 0.045%
Elongation 20-21% Ferrous 97-98% Factor of Safety 2.5

Rear Impact

Deceleration 1.5g

Load 2500N

Max Stress 125.86 Mpa

/Displacement /6mm

Factor of Safety 2.4

ERGONOMICS

Comfortable
Drive Space
Low vibrations

Optimal Steering Wheel

Position

Particulars Angles
Knee angle Kill Switches

Elbow angle
Use of Elastomers
Neck angle Low Centre of
Gravity
Ankle angle
ENGINE AND POWER TRANSMISSION
 Briggs and Stratton 550 series 3.5HP 127cc Engine S.NO SPEED CVT SPROKE FINAL TRACTIV
is used in Our Kart (RPM) RATIO T REDUCTIO E FORCE
 CVT(continuously variable transmission) of TVS RATIO N N
Streak is used for better Power Transmission  1  1850  16  0.66 10.56 566.929
2  2750  10  0.66 6.6 354.33
S.N CONFIGURATION VALUE  3  3600  6.4  0.66 4.224 226.77
O • MAXIMUM SPEED OF THE KART:
1 GROSS TORQUE 7.5Nm@2600
2 MAXIMUM POWER 3.5HP@3600 SPEED=
3 TRANSMISSION(CVT) SPROCKET RATIO(0.66)
= =12.46 =44.86Kmph
4 DIAMETER OF THE 0.2794m
WHEEL
• DRIVE TORQUE=Engine torque*reduction*
5 MAXIMUM SPEED(no 44.86Kmph
 load)
Assuming transmission efficiency=80%
  =7.5*16*0.66*0.8 =63.36Nm
 Gross weight of the kart=160kg • DRIVE FORCE=drive torque/radius of wheel

• Number of teeth on CVT output =54 =63.36*1000/5.5*25.4 =453.54 N

• Number of teeth on rear shaft sprocket=36 • ACCELERATION:=Force/mass
• Ratio=0.66:1  
=453.54/160 =2.83
WHEEL ASSEMBLY RESULT, SELECTION AND SIMULATION.
• Slick type tires that can maintain good speed in dry weather conditions
are used.
• Light Alloys are used as rim material.
• Weigh Distribution ratio is 2:3 (Front : Rear)
• Nylon is used for tire material.
Specifications
Weight Distribution
Front Diameter 254 mm
Rear Diameter 279.4 mm On front axle : (2*1569.6)/5=627.84
Front Width 114.3 mm On rear axle : (3*1569.6)/5=941.76
Rear Width 190.5 mm
Rim Diameter 139.7 mm
 BRAKING
FORMULAE:
S.No DESCRIPTION 1.Brake line pressure:
1 Mechanism used Hydraulic = force on the brakes / area of master cylinders (as pedal ratio is 4:1)
= pedal ratio *force on the pedal / area of Master Cylinder
2 Wheel base 1397mm 2.Clamping force:
3 Disc diameter 200mm CF= brake line pressure *(Area of caliper piston * 2)
3.Rotating force:
4 Master cylinder diameter 10 mm R.F=C.F* Number of calipers * coefficient f friction of brake pads
5 Caliper piston diameter 25.4mm 4.Braking Torque (Tn) = Braking force* disc radius
5.Braking force= clamping force * coefficient of friction
6 Pedal ratio 4:1 6.Net work done = Change in kinetic energy
7 Brake line pressure 17825753N/m2 Force *distance=1/2*m*vi 2 – ½*m*vf 2
(Clamping force - frictional force of road) * distance=1/2*m*v i 2 – ½*m*vf
8 Clamping force 1864.4 N
Stopping distance:
9 Rotating force 10838.6 N DS =1.79meters
10 Braking torque 975 N-m
11 Braking force 6982.1N
12 Stopping distance 1.79meters
Brake disc

CONSIDERATIONS:
1. Weight of vehicle(with load conditions)=160kg=1569.6N
2. Weight distribution ratio =2:3.
3. Coefficient of friction between tires and dry flat concrete =0.8.
4. Coefficient of friction between brake pads and disc =0.3
5. Maximum velocity of vehicle =45 km/h =12.5m/s.
6. Brake fluid used in our braking system is DOT 3.
Steering System
Objectives
• Low Turning Radius
• Less Effort of Steering
• Increasing more straight line COMPONENTS DIMENSIONS
Tie Rod 14 inch x 0.5 inch ϕ
stability
King-Pin 3 inch x 1.5 inch x 11mm ϕ
Calculations Bracket 3.5 inch x 2.5 inch x 0.5 inch
Pit man arm 1 inch x 2 inch x 10 mm ϕ
 Inner lock angle (θ) = (total steering wheel rotation * 360) / steering ratio = 60 degrees
Bolt 10 mm ϕ
 Outer lock angle(ϕ)= cot ϕ – cot θ= w / l = 29.5 degrees Steering shaft 20 inch x 1 inch ϕ
Steering wheel 10 inch ϕ
 Ackerman angle calculation: Tan α = (sin ϕ – sin θ) / (cos ϕ + cos θ – 2) = 30.54
degrees GEOMETRY VALUES
Caster Angle 12 degrees
 Ackerman inside angle: Ψ = tan-1 (WB / (WB / tan ϕ – TW)) – ϕ = 16.34 degrees
Camber Angle 0 degrees
 Ackerman percentage: %Ackerman = ((inside angle - outside angle) / (Inside 100% King pin Inclination 10 degrees
Ackerman)) * 100% = Combined Angle 10 degrees
Toe-in 5 degrees
 Turning radius(R max)calculation:- Scrub Radius 9 mm
R min = length of wheel base / tan θ = 0.806 m Minimum Turning Radius 0.806 m
Maximum Turning Radius 2.37 m
R max 2= [R min + Wheel track width] 2 +Length of wheel base 2] = 2.37 m
 Project: Go - Kart (SUPER IGNITE) Date: 11-Aug-15
FMEA
Shravan kumar Uday kumar Gopi Krishna Ajay Murthy Prepared by:  
Team:
Ne Ne
Process Potential failure SE OC DE Responsibility New w w New
Potential failure effects Potential causes Current process controls RPN Actions recommended Actions taken
step mode V C T (target date) SEV OC DE RPN
C T

Who is responsible
What causes the What are the existing What are the actions for reducing the What were the actions
What is the impact on the for the
In what ways can step to go wrong? controls that either prevent occurrence of the cause or for implemented? Include
What is the customer if the failure recommended
the step go 10 (i.e., How could 10 the failure mode from 10 1000 improving its detection? You should completion month/year 10 10 10 1000
step? mode is not prevented or action? What date
wrong? the failure mode occurring or detect it provide actions on all high RPNs and (then recalculate
corrected? should it be
occur?) should it occur? on severity ratings of 9 or 10. resulting RPN).
completed by?

Leakage in Brake failure/Risk of Damage in Diff. master cylinders for

Braking 8 5 6 240 Repair / Replace Pavan Karanam Cylinder replace 8 5 5 200
cylinder accident/Vehicle damage cylinder each brake

Hydraulic hoses Brake failure/Risk of Excess pressure Sravani

  8 6 Standard hoses 6 288 Repair / Replace Hoses replace 8 6 5 240
oil leakage accident/Vehicle damage in the Hoses Kommaraju

Satyanarayana
Welding welding breakage Sudden misalignement 8 excess Load 4 Unequal a arms 5 160 Replace Replace 8 4 4 128
Murthy
Weld Breakage Brakage 10 Impact 5 TIG welding 4 200 Reweld Uday kumar Re-weld 10 5 3 150
piercing by
Tyre Deflate Inability to drive 7 8 Hosier tire 3 169 Replace/ repair Manoj Replace 7 7 2 98
objects
Damaged fuel
Fuel Fuel Leakage Engine stops 8 6 Standard size 4 192 Repair / Replace Ajay Yeso Repair 8 6 2 96
pipe/joints
Poor milage / harmful for Dirt inside the Standard air filter (Briggs
Engine air filter failure 7 6 6 252 Clean / Replace Srijan rao Clean 7 6 4 168
cylinder, piston pipe and stratton)
Continuous
  over heating Harmful for Engine 6 8 Air cooling 2 96 Use cooling system vishnu vardan Air cooling 6 5 2 60
working
mounting points loose monting
  exessive vibration / noise 8 6 high strength nut bolts 6 288 washers Sri ram washers used 7 6 4 168
failure nut
  Chain vehicle stops 6 loose or tight 5 mount properly 5 150 Repair / Replace Sri teja replace/ repair 6 4 4 96
Excess use of
  wire break inability to accelerate 8 4 Standard wire 6 192 Repair / Replace Replace 8 4 4 128
acc. Wire
end of tie rod high impact
Steering no steer 8 6   6 288 Repair / Replace Ajay Yadav Replace 8 4 5 160
breaks forces
Steering linkage high impact
  no steer 6 4 1 to 1 linkage 3 72 Repair / Replace Vidya Sagar Replace 6 4 2 48
 Design Validation Plan   
Team name: SUPER IGNITE College Name: GURU NANAK INSTITUTE OF TECHNOLOGY
Car Number: Not Defined Time period for testing: 30 DAYS
Responsibility: T. SATYA NARAYANA MURTHY  
Vehicle owner: TEAM CAPTAIN DVP Creator PAVAN KUMAR Supervisor HEAD OF DEPARTMENT,
GNIT
Vehicle Design: GOPI KRISHNA Incharge:
Technical Assistant: MANIDEEP DVP Validation Approver Asst.prof. Jayanth Engineer:  
Program Manager: RAMA KRISHNA Project Manager MONCY GEORGE Faculty Advisor: Asst.prof.SHAIK HIMAM
SAHEB
Report
No. Procedure Description Acceptance Criteria Responsible Person Test Resource Start Date Finish Date Remarks
Nos
Material IS 1161 GOOD WEIGHT TO 28/04/2015 04/05/2015 FEASIBLE 3
1 Selection SATYANARAYANA UTM
STRENGTH RATIO MATERIAL
Development of EASY TO SOLIDWORKS
2 AJAY EASY TO FABRICATE
Design SOLIDWORKS MANUFACTURE SOFTWARE 28/04/2015 13/05/2015 3
NO DEFORMATIONS
LOW STRESS AT
3 AND CRACKS UDAY KUMAR ANSYS SOFTWARE
IMPACT LOADS
Design Analysis ANSYS DEVELOPED 13/05/2015 28/05/2015 4
ACHIEVED STEERING ACCURATE
4 AJAY YADAV TRAIL AND ERROR
Steering System ACKERMANN RATIO 1:1 24/05/2015 06/08/2015 TURNING RADIUS 3
ACHIEVED STOPPING GOOD STOPPING
5 PAVAN KUMAR THEORITICAL
Braking System DISC BRAKE DISTANCE UNDER 4 m 06/01/2015 07/05/2015 DISTANCE 2
Power ACHIEVED THE
6 SRIJAN RAO TACHO METER EASY TO DRIVE
Transmission CVT REQUIRED TORQUE 06/05/2015 15/07/2015 4
Electrical POWER INDICATION AND
7 DORA DEEPAK EDC LAB RELIABLE
Systems SUPPLY ERROR ELIMINATION 07/12/2015 18/07/2015 2
LAYOUT OF PRODUCTION AT
8 OPTIMUM COST RAMA KRISHNA MARKET SURVEY
Business Report INDUSTRY 06/01/2015 15/08/2015 LOW COST 3
REDUCES IMPACT ON BASIC SAFETY DURING
9 GOPI KRISHNA
Innovation ELASTOMERS CHASSIS CALCULATIONS 20/07/2015 31/07/2015 COLLISIONS 2
 Day wise plan
GANNT CHART Days Tasks
Machine/Equipment/
Material Used Team Member
7-Mar 26-Apr 15-Jun 4-Aug 23-Sep 12-Nov 1-Jan 20-Feb Tools used
TEAM FORMATION 30 TEAM FORMATION - - GOPI KRISHNA
SATYANARAYANA
- -
5 TEAM ORIENTATION MURTHY
CONCEPT STUDY 20 CONCEPT STUDY - - SHRAVAN KUMAR
30 MARKET SURVEY - - UDAY KUMAR
SOLID WORKS AND SHRAVAN KUMAR
-
DESIGN AND ANALYSIS 123 DESIGN AND ANALYSIS ANSYS AND AJAY
STARTING DATES
25 GO-KART FRAME SOLID WORKS IS 1161 AJAY
DAYS 15 STEERING GEOMETRY AUTO CAD ALUMINIUM VIDYA SAGAR
STEERING GEOMETRY GEARS & CHAIN CVT SRIJAN RAO
TOTAL NUMBER 40 POWER TRAIN
OF DAYS 35 BRAKES AND WHEELS DISC & CALLIPER CAST IRON PAVAN KUMAR
BRAKES AND WHEELS 15 ANALYSIS ANSYS - GOPI KRISHNA
MATERIAL - - -
40 PROCUREMENT
MATERIAL PROCUREMENT 20 PHASE-1 RAW MATERIALS PIPES IS1161,MS1020 RAMA KRISHNA
15 PHASE-2 PRE FABRICATED MANUAL - SRI RAM
15 PHASE-3 TESTING UTM - PUSHYARAG
PHASE-2 PRE FABRICATED DRIVER AIDS AND SAFETY KIT - SHRAVANI
20 INSTRUMENT
FABRICATION AND - - -
DRIVER AIDS AND INSTRUMENT 50 ASSEMBLY
WELDING
IS1161 ANIRUDH
15 CHASSIS MACHINES
ROLL CAGE
DISC CALLIPER, TYRES
SPANNERS VISHNU
15 WHEELS AND BRAKES AND RIMS
POWER TRAIN 15 POWER TRAIN SPANNERS CVT SRIJAN RAO
STEERING COLUMN
SPANNERS AJAY YADAV
10 STEERING AND STEERING WHEEL
INSTRUMENTATION INSTALLATION INSTRUMENTATION SCREW DRIVERS
- DEEPAK
10 INSTALLATION AND SPANNERS
30 TESTING - - -
TEST DRIVE SATYANARAYANA
MANUAL -
15 TEST DRIVE MURTHY
ANALYSING FOR MANUAL - SHRAVAN KUMAR
REPAIR AND MODIFICATION
20 IMPROVEMENT
REPAIR AND MANUAL - GOPI KRISHNA
MARKETING STRATGIES
15 MODIFICATION
143 MARKETING - - -
MONCY,SNEHA AND
PPTs,CHARTS -
80 MARKETING STRATGIES SRI TEJA
COST S.No Systems Materials Processes Fasteners
Fluid & Brake
Tooling Total

REPORT
Miscellaneous,
Innovation
4%
Brake System
1 Brake System
Engine and
ALLOY
CAST IRON
Fitting Disc Spanner 5,000

5% 2 Transmission SLEEVE Fitting Bolts & NutsSpanner 21,600

Fit & Finish
3 Frame IS 1161 Welding Filler Weld Rod 1,750
43% Engine and 4 Body NYLON Riveting Rivets Cutter 6,000
Transmission Cutting
21% 5 Instruments & Wiring COPPER Wiring Clamps & Screws Plier 2,000
6 Steering System IS 1161 Welding Filler Spanner 5,000
7 Suspension & Shocks NA NA NA NA NA
8 Wheels & Tires ALLOY Fitting Bolts & Nuts Spanner 14,000
Miscellaneous, Fit &
9 Finish NA Riveting C-Clamps Cutter 45,000
Frame Glass E-Fibre
Body2% 10 Innovation & Coroplast Welding Filler Weld Rod 4,500
6%
Instruments &
  Total         104,850
Wheels & Tires Steering Wiring
System
13% 5% 2%

Cells & Departments

Department Time Time for No of No of
for machiner skilled non
labor y (min) labor skilled
BUSINESS PLAN (min) labor

INFRASTRUCTURE Chassis 15 10 3 2
Engine 8 4 2 1
Selection of area Machinery &Instruments required Transmission 7 4 2 1
• Plant Location:- Semi Urban Area MACHINERY:- INSTRUMENTS Breaks 6 4 2 1
Lathe Machine – 2 Milling Machine- 1 Screw Guage - 2 Steering, 4 2 2 1
Electric
Grinding Machine -1 Drilling Machine-1 Rulers -2
• Area Required:- 5500 Sq Ft ARC Welding -1 TIG Welding-1 Vernier Callipers -2
Seat ,Tyres,fit 5 3 0 3
s
Grinding Machine -1 Slotting Machine -1 Micrometers -2
Pdi 3 0 1 0
Plant Layout & Production
Processes Sales & Marketing Finance Management
Seats Pits Fuel Tank& Initial Investment
Administration office
Steering & Electrical
Department
Tyres Fitting • DELPHI TECHNIQUE Resource Investment
& staff section,
material supply • DEMAND Land Cost 50,00,000/-
Post Development
FORECASTING 
Brake Systems Inspection Equipment & Shipping 30,00,000/-
Grinding Machine Stock Yard
Infrastructure Cost 50,00,000/-

Slotting Machine Transmission Assembly Testing Instruments

Targeted Customers Total Initial Investment 1,30,00,000/-
Departments For one day :-
Cost of each go-kart=80,000/-
Milling Machine Engine Assembly &
• Students Number of go-karts units per day =10
Fitting Drilling Machine
• Upper Middle Class Total cost of go-karts per day =80,000*10
=8,00,000/-
• Race enthusiasts For one month :-
Cutting Machine
Chassis Welding
Lathe Machine Number of working days in a month =22days
ARC & TIG
Total cost for one month =22*10*80,000
=1,76,00,000/-
• JUST IN TIME Category Strategy Cost of scrab removal =25,000/-
Machinery cost =25,00,000/-
Business Good quality and safety Electricity charges =20,000/-
Inventory Management strategy with less price. Managers wages =1,75,000/- (Number of managers =7)
Labour wages =2,43,000/- (Number of labours =21)
Customer Production at low cost.
Transportation cost =45,000/-
Year Raw Work In Finished Total advantage Promotion cost =30,000/-
Material Progress Goods Investment
Promotion Advertising and trial runs. Total cost =2,06,38,000/-
strategy Calculating the cost of each=2,06,38,000 / 220
2015- 1548 31 Lakhs 2112 1615 Lakhs =93809/-
16 Lakhs Lakhs Production Available at all major Profit -10%(expected) =9380.9/-
strategy cities. Profit per month =9380.9*10*22
Days 30 30 0 365 =2,063798/-
Price Price offer at 10% less Profit per year =20,63,798*12 =2,47,65,576/-
strategy than market competitors. ANNUAL TURNOVER =1,30,00,000+2,47,65,576
=3,77,65,576/-
College level Manufacturing and Design Facilities
Machine Tool Lathe Machine Shaping Machine
·      
Slotting Machine Milling Machine Grinding & Drilling
Machine
Workshop Carpentry Fitting Sheet Metal House Wiring Bending

Manufacturing Foundry Black smithy ARC Welding Band Saw

Engg Laboratory Instrumentation & Thermal & Heat Metrology & Strength of
CAD/CAM Transfer Material Material &
Science Hydraulics

BAND SAW MILLING DRILLING WELDING

CAD/CAM LAB NDT CENTER

MILLING,SLOTTING & SHAPING
    Innovation and Conclusion
ELASTOMERS (IMPACT ABSORBER):
An elastomer will undergo an immediate, linear and reversible response to high strain to an applied force. Reversibility and
immediate response is obtained with macromolecules that have flexible chains with weak intermolecular forces.
•Elastomer shocks use a compressible rubber like material with one end pushing against a cap at the top of the tube, and the
other against the bottom of the fork.
•The sleeve moves up and down within the larger tube of the bottom of the fork as the elastomer compresses and rebounds.
•Advantages: Recyclable, quick absorption of shocks and hence smoother ride, light weight, reliable, easy to replace, less
vibrational forces and noise.
GLASS E-FIBRE:
Glass fibre is a material consisting of numerous extremely fine fibers of glass.
•         High strength, High stiffness,Relatively low density, Non-flammable,Resistant to heat.Good chemical resistance,
 Able to maintain strength properties over a wide range of conditions,Good electrical insulation
COROPLAST
Coroplast Fairing is cheap and easily available. It is shock and waterproof as well. Coroplast is a high-quality polypropylene twin-
wall profile sheet formulated specifically for use in the screen printing, display and packaging markets.
coroplast fairing provides safety as it is fire and heat resistant
Cost of this segment:-
Elastomers costs around Rs. 1100/-, glass-e fiber costs Rs. 500/- and coroplast is
About Rs. 300/-.
CONCLUSION:
While designing this go kart we have learnt many things which aren’t possible in our classrooms. We
believe we have the right team structure & spirit to design our go-kart, and we look forward to
participate in the final round of GKDC.