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Comparison of chassis frame design of Go-Kart vehicle powered by internal

combustion engine and electric motor

Article in Materials Today Proceedings · September 2020

DOI: 10.1016/j.matpr.2020.07.504

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Comparison of chassis frame design of Go-Kart vehicle powered by

internal combustion engine and electric motor
Naveen Kumar Chandramohan a,⇑, Mohanraj Shanmugam b, S. Sathiyamurthy c, S. Tamil Prabakaran d,
S. Saravanakumar c, V.S. Shaisundaram e
a
Department of Automobile Engineering, Kumaraguru College of Technology, Coimbatore, India
b
Department of Materials Engineering and Nanotechnology, Politecnico di Milano, Milan, Italy
c
Department of Automobile Engineering, Easwari Engineering College, Chennai, India
d
Department of Mechanical Engineering, Government College of Engineering, Bargur, Tamilnadu, India
e
Department of Automobile Engineering, Vels Institute of Science, Technology and Advanced Studies, Chennai, India

a r t i c l e i n f o a b s t r a c t

Article history: Go-Kart design and development helps in implying the theoretical knowledge into the practical aspect. It
Received 3 July 2020 also helps to learn about various parameters that can be altered and implied to try to improve the per-
Accepted 21 July 2020 formance of the kart. Go-kart is of various types namely internal combustion engine (IC) powered,
Available online xxxx
Electric driven, solar powered and Hybrid. This project is aimed to convert an IC engine Go-kart into
an Electric driven kart, the Frame of the IC engine kart requires a single mount as it needs only Engine
Keywords: and it is developed using SOLIDWORKS, whereas in Electric driven it is a combination of Battery,
Go-kart
Motor and Controller and hence it requires a large number of mounts and cross members to support
Electric battery
Deformation
the components, the conversion of IC powered engine frame into an Electric driven needs some alteration
IC engine to support the components and a new frame was developed using SOLIDWORKS. Both frames are anal-
ANSYS ysed using ANSYS for different types of impacts namely front, side and rear in accordance with the load
SOLIDWORKS distribution that acts in the frame and the deformation results are compared.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Newer Trends and Innovation in Mechanical Engineering: Materials Science.

1. Introduction 2. Frame

Go-kart is a small racing vehicle with no suspension and rarely 2.1. Frame material
used with differential [1–4]. Karting is often used as a free time
sport and it comes under Formula 9 category [5–8]. Go-kart is of The material used is AISI 1020 carbon steel for our frame
various types such as Internal combustion engine, Electrical pow- because of its high tensile strength, best weld ability, machinability
ered, Solar Go-kart and Hybrid Go-karts. Nowadays due to extinc- and high toughness [21,22]. The chemical composition of the
tion of Hydrocarbons and increasing pollution Green concept is material is as follows Table 1.
becoming popular and the world is expected to switch to com-
pletely Electric sourced vehicles [9–14]. 2.2. Design OF chassis frame for IC engine
This work aims to convert an existing IC engine Go-kart into an
Electric powered by making changes in the frame to accommodate Frame is designed using SOLIDWORKS 2016 to achieve best
electrical components and to study the deformations that occurs optimum geometry with less design errors Fig. 2.1.
during the conversion [15–20]. Both IC and Electric frames defor-
mations are compared. 2.3. Frame safety analysis

⇑ Corresponding author. The structural integrity of the frame was verified by comparing
E-mail addresses: [email protected], [email protected] the analysis results with the Standard values of the material. Anal-
(N.K. Chandramohan). ysis was conduct by use of finite element analysis FEA on ANSYS

https://doi.org/10.1016/j.matpr.2020.07.504
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Newer Trends and Innovation in Mechanical Engineering:
Materials Science.

Please cite this article as: N. K. Chandramohan, M. Shanmugam, S. Sathiyamurthy et al., Comparison of chassis frame design of Go-Kart vehicle powered by
internal combustion engine and electric motor, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.07.504
2 N.K. Chandramohan et al. / Materials Today: Proceedings xxx (xxxx) xxx

Table 1 2.3.3. Front impact

Chemical composition of the frame material. The impact force at a speed of 60 km/hr for a collision time of
S. NO PARAMETER RESULT 1.05secs in the front region of our frame by applying constraints
1. Carbon 0.18–0.23% at the rear end. Since,
2. Manganese 0.30–60% a =(60–0)/1.05
3. Phosphorus 0.045max =(60  1000)/(60  60  1.05)
4. Silicon 0.07–0.6% =15.87 m/s2
5. Sulphur 0.05max
Therefore,
F = 200  15.87 = 3174 N

2.4. Result

Fig. 2.3, Fig. 2.4, Fig. 2.5, Fig. 2.6.

Fig. 1. Isometric view of frame.

WORKBENCH 16.2 software. To conduct finite element analysis of

the chassis a CAD model of the designed chassis was uploaded
from SOLIDWORKS 2016, the stress was calculated by simulating
different induced load cases.
The load cases simulated were:

1. Front impact
2. Rear impact
3. Side impact Fig. 2. Meshed view of frame.

2.3.1. Pre-Processing
Meshing
Mesh quality: Fine mesh
No. of Nodes: 304,369
No. of Elements: 124,866
Fig. 2.2.

2.3.2. Calculations
The impacts are purely elastic collision and the velocities for the
impact test were taken according to International Journal for
Mechanical and Industrial technology.
F ¼MA

A ¼ ðV  U Þ=T

Factor of safety ðFOSÞ ¼ Yield stress=Working stress

Where,
F – Impact force applied on the vehicle
m – Mass of the vehicle with driver (120 kg + 60 kg = 180Kg)
a – deceleration (negative acceleration)
u – Initial velocity
v – Final velocity
t – Collision time Fig. 3. Total deformation of front impact.

Please cite this article as: N. K. Chandramohan, M. Shanmugam, S. Sathiyamurthy et al., Comparison of chassis frame design of Go-Kart vehicle powered by
internal combustion engine and electric motor, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.07.504
 N.K. Chandramohan et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

Fig. 7. Meshed view of frame.

Fig. 4. Equivalent stress of front impact.

Fig. 8. Load acting on the frame in front impact.

Fig. 9. Deformation due to front impact.

Fig. 5. Total deformation of side impact.

Fig. 10. Equivalent stress due to front impact.

Fig. 6. Equivalent stress of side impact. Fig. 11. Load acting on the frame at rear impact.

Please cite this article as: N. K. Chandramohan, M. Shanmugam, S. Sathiyamurthy et al., Comparison of chassis frame design of Go-Kart vehicle powered by
internal combustion engine and electric motor, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.07.504
4 N.K. Chandramohan et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 12. Deformation due to rear impact.

Fig. 17. Graph of equivalent stress of IC and electric frame.

Fig. 13. Equivalent stress of rear impact.

Fig. 14. Load acting during side impact.

Fig. 18. Graph for FOS of IC and electric vehicle.

2.4.1. Results for Electric vehicle frames

Fig. 15. Equivalent stress due to side impact. Fig. 2.7, Fig. 2.8, Fig. 2.9, Fig. 2.10, Fig. 2.11, Fig. 2.12, Fig. 2.13,
Fig. 2.14, Fig. 2.15.

3. Conclusion

To convert an IC engine powered Go-Kart into Electric powered

Go-Kart there are a lot of parameters to be considered like in this
case the battery chosen is Lead acid battery where the load of
the battery is to be considered along with Electric motor which
increases the vehicle load as well, so the frame is bit heavier in this
case. When the deformation of the vehicle is compared due to less
weight the Conventional IC powered has shown less deformation,
which decreases linearly from Front, rear and then on to the side.
But the deformation on the front is less for the Electric than the
IC powered Fig. 3.1, also the equivalent stress is less for IC powered
by considering all the three impacts Fig. 3.2. Even though the Elec-
tric go-kart has been heavier compared to the IC the frame design
is proved to be safe with a factor of safety nearly equal to 2 which
Fig. 16. Graph of deformation of IC and electric Go-Kart frame. is shown in the graph Fig. 3.3.

Please cite this article as: N. K. Chandramohan, M. Shanmugam, S. Sathiyamurthy et al., Comparison of chassis frame design of Go-Kart vehicle powered by
internal combustion engine and electric motor, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.07.504
 N.K. Chandramohan et al. / Materials Today: Proceedings xxx (xxxx) xxx 5

Declaration of Competing Interest [11] V.S. Shaisundaram, L. Karikalan, M. Chandrasekaran, Experimental

investigation on the effect of cerium oxide nanoparticle fuel additives on
pumpkin seed oil in CI engine, Int. J. Veh. Struct. Syst. (IJVSS) 11 (3) (2019).
The authors declare that they have no known competing finan- [12] R. Muraliraja, J. Sudagar, R. Elansezhian, A.V. Raviprakash, R. Dhinakaran, V.S.
cial interests or personal relationships that could have appeared Shaisundaram, M. Chandrasekaran, Estimation of Zwitterionic surfactant
response in electroless composite coating and properties of Ni–P–CuO
to influence the work reported in this paper.
(Nano) coating, Arab. J. Sci. Eng. 44 (2) (2019) 821–828.
[13] R. Akash, R. Muraliraja, R. Suthan, V.S. Shaisundaram, Synthesis and testing of
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Please cite this article as: N. K. Chandramohan, M. Shanmugam, S. Sathiyamurthy et al., Comparison of chassis frame design of Go-Kart vehicle powered by
internal combustion engine and electric motor, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.07.504
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