INTRODUCTION

CHAPTER-1

Generally, go-kart is a very fun to drive, it works on a simple structure about the chassis
which is base of go-kart is made by different type of materials (alloy steel), after that this car
includes various types of I.C engines according to the power consumption. Mostly go karts
uses clutch system for that transmission is attached to engine at rear axle. In go kart small
steering system uses, this is approximately 12inches. Tires in this car usually small as
compare to normal car tires, they are able to work in both wet and dry road conditions.
Modeling and Design are performing in solid works, CATIA, and ANSYS, go-kart racing
organize by NKRC (National Kart Racing Competition) in Nagpur and Hyderabad. This
paper concentrates the study and examines the go-kart working mechanism.The objective of
this paper is to study and implement the working mechanism of Go-Kart with some modern
technique respectively.

Keywords: - Go kart, SOLID WORKS, CATIA, FUSION 360 and ANSYS, NKRC.
A small wheeled go-kart consists a small engine, single seat and the most important part
chassis which is characterized by the light and strong material and absence of suspension
system so the performance on the chassis of go-kart. Go-Kart used as a very popular, cheaper,
and smaller way of automobile racing. It is usually used as a low cost and lot of safer way as
compare to other motor
sports such as Formula one. There are many people which are link it with young drivers, but
apart
from youngster, adults are also active in this Karting. Craze of Go-Kart is continuously
increasing
day by day. With continuous improvement go-kart industry will surely obtain a very bright
ranking of popularity in the future in designs, technologies and racing tracks. There are four
major components of go-kart: i. Chassis, ii. Engine, iii. Steering System, iv. Braking System,
v. Chassis of go-kart is the base in which engine, operator seat and steering system mounted.
It is a
skeleton frame made up of pipes and other materials with different shapes. Chassis of go-kart
must of popularity in the future in designs, technologies and racing tracks. There are four
major
components of go-kart: i. Chassis, ii. Engine, iii. Steering System, iv. Braking System, v.
Chassis
Chassis of go-kart is the base in which engine, operator seat and steering system mounted. It
is a
skeleton frame made up of pipes and other materials with different shapes. Chassis of go-kart
must have stability, torsional rigidity, impact forces as well as it should have high degree of
flexibility without suspension and it should be feasible to bear a sustain load of accessories
and operator Chassis should be designed for safety purpose without any compromising the
structural strength
All knows that engine is used to give power to the wheels of the vehicle. Amusement go-kart
cars
consist of 4-stroke engines or electric motors while in racing go-karts 2-stroke engines is used
which is powered by 2 to 10 hp [3]. In today world BRIGGS AND STRATTON 127cc units
engine is very popular for racing of go-karts and this is our proposed engine for project. This
kind of engine is adequate for racing and fun activities
Steering system is just a mechanical arrangement to ensure that the front wheels are
approaching
desired direction. The main mechanism is rack and pinion steering mechanism where pinion
gear is turn by steering wheel and pinion moves on the rack [4]. Another modern technology
is to adjust thesteering according to the comfort of operator. In older design the recirculating
ball were uses and this mechanism is still found in modern trucks and utility vehicles. In go-
kart car 12-inch steering which is standard size is used normally Braking System In this
variationofspeedthere is a major role of braking system, normally braking system is used to
control or deform the speed of vehicles. The braking system is used to provide the enough
braking force to completely lock the wheels [4]. In modern time the disc brake is in high
trend, when the disc brake applies the calipers squeezes the pairs of pads against the disc. In
that case the friction retards the rotation of shaft such as vehicle axle. Generally, brakes are
applied to rotating wheels but they can take another form such as surface of moving fluid
 CHAPTER-2
Literature Review
Halderman D.J et al says that the chassis is the framework of vehicle in whichengine,
transmission,final drive components are mounted on the chassis. So the chassis should be strong
and bearable for the suspension and operator. Mitchell et al. [4] studied that the wheel base of the
vehicle is the center distance of the front wheel to the center of the rear wheel when we take view
from the side. Long wheelbase vehicle is much smoother and stronger than the short wheelbase
vehicle and it increases the stability of vehicle from the cornering. Martin says that every karter
has responsibility to determine its own requirements or needs.he has also responsibility to stay in
spirit and stay with the rules in which he is participating. Setting of go-kart chassis increase our
theory knowledge as well as our practical knowledge and it should be improve time to time
Koustubh analyze that the design of chassis act as an important role and it can develop

many skills in designing software like FUSION 360. From the analysis it can predict that the
chassis
is safe to bear stresses or not and also seeing the deformation and modification in chassis design.
Harshil et al. [6] examined that the engine and aerodynamic designed easily propel the speed of
go-kart car. Braking system designed is act as vital role to stop the rear wheels safely and easily
at
higher speed. Steering system has also design gives the proper turning radius at any condition and
satisfies the minimum condition of radius. According to International go-kart association, [7] an
American company became first go-kart manufacturer company in 1958 and McCulloch was the
first engine manufacturer of go-kart in same year. After that the go-kart race widely spread in
Europe and now a days it is very popular in India. Ramini et al. [8] studied that go-kart is a one
seater vehicle, its size is small but the major factor is that traditional suspension is completely
lack. There are no dampers or springs and camber and caster angles is including with tires. We
have performed many stresses test in our project to make a good and safe vehicle.

Fig 2.1 shows go-kart

 Chapter-3
DESIGN PARAMETERS
In a Go-Kart, there are mainly six parts. They are
1. Chassis

2. Engine

3. Steering

4. Transmission

5. Tyres

6. Brake

7. Electric Starter
CHASSIS

The chassis is an extremely imported element of the kart, as it must provide, via flex, the
equivalent of suspension to give good grip at the front. Karts have no suspension, and are
usually no bigger than is needed to mount a seat for the driver and a small engine. Chassis
construction is normally of a tubular construction, typically GI with different grades. In this
kart, we use GI B class tube with 1” diameter. The chassis support the power unit, power
train, the running system etc

ENGINE

An engine of a go-kart is usually a small one. About 100-200cc. In

this kart, we use a Kinetic Honda Single Cylinder 98cc 2-stroke petrol engine, which
produces about 7.7 BHP of power at 5600 rpm. We use2strokeenginebecause this is used
mileage. Only power.
STEERING SYSTEM

The steering of a go-kart is very sensitive. Because of lack of adifferential, a kart’s natural
direction of travel, forwards, is very difficultto change. However, the two rear wheels are
attached by a solid axle, andmust therefore move together, so in order to turn, one of the
wheels needto skid over the track surface. In this kart we use a special kind of steeringsystem,
disc and link mechanism. This mechanism with modification iswidely used in racing cars
especially formula one cars.In this system, the steering spindle is connected to a disk or
plateand this disk is connected to the front two wheels using two links. Whensteering rotates,
the disk also rotates and as a result, the link actuates andthe wheel will turn according to the
rotation of steering

TRANSMISSION

Transmission means the whole of the mechanism that transmits the power from the engine
crankshaft to the rear wheels. In this vehicle, the power from the engine is transmitted to the
sprockets using chain, i.e. this is chain drive. The driversprockethas12teethanddrivensprocket
has 44 teeth. Usually go-karts do not have a differential and so we eliminate differential from
our vehicle also. And also this go-kart has no clutch and gears because this is automatic
transmission. Belt and pulley type CVT is used in this kart. The power from the engine is
transmitted to the rear two wheels using chain drive. We use chain drive because it is capable
of taking shock loads.
TYRES

For go-karts, wheels and tyres are much smaller than those used on a normal car. The tyres
will have increased grip and a hard one. And also it can withstand the high temperature. In
this kart, we use tyres having 14” dia for front and 16” dia for rear. This is used for an
aerodynamic shape. The tyres must have pressure of at least 18 psi.
BREAK
Typically, go-karts will have single rear drum brakes, which is situated on the rear axle. The
brake will capable for stopping the kart running in 40 mph. The pedals actuated by the left leg
operate the brakes

Electric Start

Both Otto cycle and Diesel cycle internal-combustion engines require the pistons to be
moving before the ignition phase of the cycle. This means that the engine must be set in
motion by an external force before it can power itself. Originally, a hand crank was used to
start engines, but it was inconvenient and rather hard work to crank the engine up to speed. It
was also highly dangerous. Even though cranks had an overrun mechanism to prevent it,
when the engine started, a crank could begin to spin along with the crankshaft. The operator
had to pull away immediately, or else risk a broken wrist, or worse. Moreover, as engines
evolved, they became larger and compression ratios increased, making hand cranking an
increasingly difficult matter.

Electric starter

The modern starter motor is a series-wound direct current electric motor with a solenoid
switch mounted on it. When low-current power from the starting battery is applied to the
solenoid, usually through a key operated switch, it pushes out a small pinion gear on the
starter motor's shaft and meshes it with the ring gear on the flywheel of the engine. The
solenoid also closes high current for the starter motor and it starts to run. Once the engine
starts, the key-operated switch is opened, a spring in the solenoid assembly pulls the pinion
gear away from the ring gear, and the GO - KARTING starter motor stops. Modern starter
motors have a "bendix" — a gear and integral freewheel, or overrunning clutch, that enables
the flywheel to automatically disengage the pinion gear from the flywheel when the engine
starts.

STA RTER MOTOR ASSEMBLY Other than the main parts, the kart also contains some
parts such as Mufflers. The muffler we use is Baffle type. In baffle type, the exhaust gas
passes through a series of baffles, which causes maximum restriction and hence back
pressure. The noise reduction takes place because the length of travel of exhaust gases
increases considerably. Other main part is the headlight. Head light is provided at the front
of the kart for sane night racing. Also there is a plastic seat in the kart for the driver. The kart
is single seated. There is also a bumber in front of the kart
 CHAPTER-4
SYSTEM USED IN GO- KART

FUEL SYSTEM
The purpose of fuel system in SI engines is to store and supply fuel and then to pump this
fuel to carburetors. The fuel supply system also prepares the air-fuel mixture for combustion
in the cylinder and carries the exhaust gas to the rear of the vehicle. The basic fuel supply
system used in the vehicle consists of the following.
a) Fuel tank
b) Fuel strainer or Fuel filter
c) Air cleaner
d) Carburator

Chemistry of Combustion
The type of combustion that takes place in an engine is commonly called Burning. Burning is
an example of chemical change. In a chemical change as substance losses those characteristic
by which we recognize it and is changed to a new substances with different properties. The
petrol is burned in the engine and the products that result no longer resemble petrol.The
petrol in the fuel lines differs from the petrol that is drawn into the engine. As it passes
through the carburetor and intake manifold and is mixed with aim some of the petrol is
changed from liquid to vapour. This process of vaporization is called a physical changed. No
new substance is formed since the petrol vapour is still recognized as petrol. Diesel fuel oil
and petrol are both mixtures of volatile hydrocarbons compounds of hydrogen and carbon. A
compound is a substance that can be separated by chemical means into two or more simpler
substances. Hydrogen and carbon are examples of elements. In chemistry
anelement is defined as a substance, which cannot be separated into simpler
action
Fuel Tank - It is reservoir of fuel oil for an engine. It is kept in and elevated position so
that the fuel will flow to the carburetor through the filter by gravity. Our fuel tank has a
capacity of 1 litre and there is also a fuel level indicator in it.

Fuel Filter - Dust, particles of dirt or other unwanted particles might be present in the
petrol. This petrol should be free from these particles. Therefore, the petrol filter is used.

Air Cleaner - Since the atmospheric air is highly cornices and contains dust and dirt
particles, it is allowed to enter the engine intake manifold only through an air cleaner.

Carburetor - The mixture of petrol and air burns in the combustion chamber of the engine.
The carburetor is a device to mix the petrol with air in the proper ratio for the purpose of
combustion. The quantity of petrol and air can be indifferent ratios. The quantity of petrol can
sometimes be more and sometimes less. The speed of the engine changes according to the
a) Meter the quantity of charge to give correct air-fuel mixture.
b) Atomize petrol into fine particles so that it burns quickl.

IGNITION SYSTEM

The ignition system used for small two-stroke engine is flywheel magneto type.
Theadvantage of this system is that it is set combined. The though ones suitable for multi-
cylinder engine have also been developed. The principles of this type of ignition can be
easilyunderstood with following saey.

Magneto Generator

Alternating electrical impulses in a low-tension armature winding or coil. At an appropriate

moment the circuit through the winding is broken by means of an interrupter, which forms an
integrate part of the magneto. A condenser connected across the breaker assures rapid
cessation of the primary current, and this results in the induction of a high tension impulse in
a fine wire secondary winding, which either surrounds the primary winding or is surrounded
by it, both being wound on a magnetic coil. An advantage of the magneto is its self-contained
character. All the demands of the system are in on compact unit from which it is necessary
only to run a low-tension cable to the lighting system and high-tension cable to the spark plug
Figure shows the different views of a single cylinder design of flywheel magneto. A small
magnet is provided with laminated pole pieces and the assemblies cast in the engine flywheel,
which also acts as a cooling fan. In addition to the magnet, the magneto consists of a coil
witha w-shaped or three pole laminated core, an interrupter and a condenser, all of these parts
being mounted on a base plate or starter plate. The two curved slots in the stator plate permit
of adjusting the spark timing
As the poles of the core pass those of the magnet, the magnetic flux passes through the coil
first in one and then in the opposite direction and alternating electric impulses are induced in
it. When the flux has been well established the primary circuit is closed and a moment later
when the primary current is at its maximum, the circuit is broken by the interrupter, which is
actuated by a cam on the crankshaft. Magnetos also have a device coupled to it so that the
timing is advanced as the engine speed increases. This helps in ignition of the charge in the
cylinder. The magnetos are either fitted with build-in type of two coils – one ignition coil and
the other lighting coil or alternately they have separate ignition coil. These are attached to a
starter or fixed plate and terminate in soft-iron pole-pieces closely matching the shape of the
flywheel which rotates around them.

Ignition Coil

The coil consists, in fact, of two coils which may be considered as separated electrically,
although they are both wound on the same iron core and share a common terminal. One coil,
known as the primary, is fed from the battery, and the principle of operation depends upon
the fact that, if the supply to this coil is suddenly interrupted, then the voltage is created or
induced in the other coil known as the secondary. The voltage in the two coil scan
consideredfor our purpose to be in the same ratio. as the number of turns of wire on the two
coils, so that by providing relatively few turns on the primary winding, and a very large
number onthe secondary the necessary, high voltage is obtained.

The voltage required to cause a spark between the sparking plug points depends upon both
the pressure of the mixture with the cylinder and the gap between the points under average
conditions a voltage of the order of 10,000 volts is needed. Earlier it has been stated that the
development of the higher voltage in the secondary winding of the ignition coil only occurs
when the interruption is arranged to take place at the correct time by the contact electricity
supplied to the primary winding is suddenly interrupted.

Spark Plug
An essential part of the ignition system is the provision of electrodes within the engine
cylinder, across which the ignition spark can discharge. It is desirable to arrange that these
electrodes shall be easily accessible and they are, therefore, mounted on a screwed-in plug. A
sparking plug consist essentially of a steel body which bears the earthed electrode, an insuor,
and a central rode which forms the other electrode, fed from the distributor. The lower part of
the body is threaded to suit a screwed bole provided in the engine, the length of the threaded
portion known as the reach and varying with the plug design. The body of the plug seats on to
a soft steel washer when it is screwed into the engine. The insulator operates under
particularly arduous condition since not only must it withstand the high ignition voltage, but
it’s lower and is subjected to the full bear of combustion and it is also liable to mechanical
shock. At one time, the insulator was mode from porcelain but modern plugs use ceramics
based on sintered aluminium.with a screwed terminal at the upper exposed end, often shaped
to accept a snap-on connector. The tip of the electrode, at which the spark occurs, usually has
an insert of heat-resisting metal such as nickel. The ignition voltage is about 25,000 volts and
the distance between the central and earthed electrodes is about. 202 inch and is adjusted by
bending the outer electrode.

LUBRICATION SYSTEM
It is a common known that if two rough surfaces are rubbed together, there is a resistance to
the motion and heat is generated. In an IC GO - KARTING engine surface whichrutogetherar
not tough by normal standards, yet if they are allowed to run in direct contact get one another,
 CHAPTER-5
SPECIFICATIONS OF A GO – KART

Engine Displacement (cc)=98 cc

No. Of cylinders=1

Type of Fuel=Petrol

No. Of Strokes=2

Maximum power (bhp)=7.7 bhp @ 5600 rpm

No. Of gears / variator=Variator

Max. Torque=1.0 kgm @ 5000 rpm

Overall Length (mm)=1650

Height (mm)=710

Wheel Base (mm)=1270

Ground Clearance (mm)=203

Kerb Weight (kg)=70

Fuel tank capacity=1 litre

Brake=Drum

Type of Cooling=Air cooling

 CHAPTER-6
DESIGN AND DRAWINGS
 PERFORMANCE STUDY
CHAPTER-7
First of all, we say that this is not a performance machine. We are taking a two – wheeled
engine and connected to four wheels. So the performance also deferrers. We tested this
vehicle at standard conditions. Engines are tested to find out the variations of Brake Horse
Power, Torque, Fuel Consumption, Frictional Horse Power and Specific Fuel Consumption at
different engine speed

1. Torque Vs RPM
From the graph, we see that during medium speeds, torque increases with speed. The
volumetric efficiency being higher during thisperiod (cylinders get enough fuel – air mixture
to burn), higher combustion pressures produce more power. At high speed, engine cylinders
induce less amount of fuel – air mixture reducing combustion pressures and hence the torque,
the curve drops down

2. BHP Vs RPM
From the graph, we see that the brake horsepower of an engine steadily increases with the
increase of engine rpm. At a certain engine speed, the bhp drops down instead of increasing.
This is due to two reasons.
1. At high speeds, the volumetric efficiency of the engine decreases considerably, i.e. it takes
in decreased quantities of fuel – air mixture producing lower combustion pressures and hence
lowers engine power.
2. We also know that frictional losses in an engine increase five times as the
engine speeds up from 1000 to 3000 rpm, decreasing the brake horsepower.
3. FHP Vs RPM
Frictional Horse Power increase in speed. Frictional loses are lower at low engine speeds.
These losses increase considerably with the increase in rpm. The horsepower lost due to
friction increases five times as the engine speed increases from 1000 to 3000 rpM.
The frictional losses in an engine may be due to friction between rings and cylinders, valves
and valve guides, timing gears, bearings, The major source of friction loss in an engine is
between piston rings and cylinder, which contributes to 70% of the total engine friction.
4. Specific Fuel Consumption Vs RPM
The specific fuel consumption decreases with the increase of engine rpm.
Thefuelconsumption per hp/ hr in the case of diesel engines is less at all engine speeds.
As shown in the graph, at engine speeds above 2,500 rpm, the specific fuel consumption
increases in both petrol and diesel engines. When engine load decreases, the specific fuel
consumption increases slightly.
Therefore, we conclude that brake fuel rate is higher for slow speed engines, increases a little
for medium speed engines and increases more for high-speed engines. This is because at low
and maximum speeds, a rich mixture is required
 CONCLUSION-8

The 98cc, 2 stroke, 4 wheeled racing car, Go-Kart, we finally made one under 25K which is a
big truth. But we made just a protype of that performance machine. The materials we used are
not up to the mark of automotive standard. Big companies will design one go-kart at a
minimum of 2 years. But we made this from two months. We do not recommend driving this
go-kart at a speed of 80 km/hour but it is best suited in 30-40 km/hour speed.
The project report is prepared in such a manner that every layman can understand the details
pertaining to the project. The report is prepared design guide line for making suitable report is
expected to prove valuable
to the successor students of mechanical engineering to know the essentials of a project
anproject report. The matter discussed in the early pages just give a broad outline of
small-scale industries. We have, tried to cover all the aspects concerned with our project
 SCOPE OF THE PROJECT-9

Go-Karting is a big craze to the Americans and Europeans. It is

initially created in United States in 1950s and used as a way to pass spare
time. Gradually it became a big hobby and other countries followed it. In
India go-karting is getting ready to make waves. A racing track is ready
in Nagpur for go-karting and Chennai is also trying to make one. Indian
companies are also producing go-karts in small scale. MRF and Indus
motors are the major bodies in karts and they are offering karts between 1
lakh and 3 lakh. But to make go-karts popular, the price must come down.
For that, many people are trying to build one under 1 lakh and we had
also take up the challenge and make our under 25 K. This is a dream
come true. A go-kart just under Rs. 25,000/-. So we are sure that our
project will have a high demand in the industry and also we are hopping
to get orders from the racing guns.
 REFERENCE-10

Automobile Engineering R. B. Gupta

Automobile Engineering Kripal Singh

Industrial Engineering and Management O. P. Khanna

Automotive Technology H. M. Sethi

Thermal Engineering M. Zakria Baig

Auto CAR Magazine, February 2004 issue

www.go-karting.com

www.howstuffworks.com

www.answers.com

www.wikipedia.org