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Chassis Report

The document provides a report on the chassis and ergonomics of Team Infinity Racers' go kart. It discusses the requirements for the chassis, including being light, having high torsional stiffness and driver protection. It outlines the chassis dimensions which were calculated based on the driver. Load estimation and material selection are also covered, with AISI 4130 steel selected for the chassis material. The chassis design section illustrates the chassis members and considerations for driver safety. Analyses of front, rear, and side impacts are presented to evaluate the chassis' performance under different loading conditions.

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Vansh Jain
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325 views11 pages

Chassis Report

The document provides a report on the chassis and ergonomics of Team Infinity Racers' go kart. It discusses the requirements for the chassis, including being light, having high torsional stiffness and driver protection. It outlines the chassis dimensions which were calculated based on the driver. Load estimation and material selection are also covered, with AISI 4130 steel selected for the chassis material. The chassis design section illustrates the chassis members and considerations for driver safety. Analyses of front, rear, and side impacts are presented to evaluate the chassis' performance under different loading conditions.

Uploaded by

Vansh Jain
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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TEAM INFINITY RACERS

CHASSIS AND ERGONOMICS REPORT


BY VANSH JAIN AND FINNY JOSE

INTRODUCTION

Chassis is crucial in any Vehicle , A good Chassis is important as it gives us a good platform and aids in
handling in a go kart
REQUIRMENTS

Chassis should be as light a possible


Chassis should have high tortional stiffness as it improves load transfer across the chassis
and improves handling
Chassis members should have minimum OD of 1inch and wall thickness 1mm
We want our wheelbase to be as short as possible according to rule book to maximize
agility = 40inch
Driver safety is crucial and chassis should protect its driver in terms of a crash
CHASSIS DIMENSTIONS

We calculated are ideal chassis dimensions by building it around the driver , so it


would be comfortable for the driver and would also give us dimensions for
when we make chassis in cad , also enabling us to not waste excess material , by
making the chassis to large or too small, there is no 95th percentile rule in IKR so
setting dimension according to the driver is very beneficial
DESIGN OBJECTIVE
 First and most important objective is to provide protection to the driver, by arranging the
frame member to yield maximum strength and torsional rigidity, while reducing weight by
avoiding the redundancy of member.
 Design for manufacturability, as well as cost reduction, to ensure both material and
manufacturing costs reduced competitive with other Go-Karts.
 Comfortable driver seating and reduce escape timing while in emergency.
 Calculation of stresses acting on the chassis of the vehicle under different loading
conditions.
 Minimum Deflection in chassis in full load condition.
 Sustain impact forces in case of accident.
 Reduction of welding joint by preferring bending

CHASSIS LOADING Frame is defined as a fabricated structural assembly that supports all functional vehicle systems.
This assembly may be a single welded structure, multiple welded structures or a combination of composite and
welded structures [1]. Depending upon application of loads and their direction, chassis is deformed in respective
manner briefed as follows [2]: i. Longitudinal Torsion

 Longitudinal Torsion

Application of equal and opposite forces act at a certain distance from an axis tends to rotate the body about the
same axis. A go kart also experience torsion while moving on road subjected to forces of different magnitudes acting
on one or two oppositely opposed corners of the cars as shown.

 Vertical Bending

Weight of driver, engine, drive-train, radiator and shell etc. under an effect of gravity produce sag in the frame as
shown
 Lateral Bending

Lateral bending deformation occurs mainly due to the centrifugal forces caused during cornering and wind forces to
some extent. Lateral forces act along the length of chassis and is resisted by axles, tires and frame members viz.
hoops, side impact members and diagonal hoops etc as shown

 Horizontal Lozenging

This deformation is caused by forward and backward forces applied at opposite wheels . These forces may be caused
by vertical variations in the pavement or the reaction from the road driving the car forward. These forces tend to
distort the frame into a parallelogram shape as shown

LOAD ESTIMATION

After literature review, it was brought in view that normally FSAE car parts are designed to withstand 3.5 g bump, 1.5
g braking and 1.5 g lateral forces [4]. These loads have to be considered individually and combined.

MATERIAL SELECTION
Selection of material makes a significant contribution in Design and Fabrication
of Go Kart as it undergoes many stresses and Deformation during the
fabrication process. During selecting any material, it is important to know what
type of material is needed and what type & amount of forces are going to act on
it. We should also note the Chemical and Mechanical properties as they are
important aspects in determination of strength of material.
Chassis is the main base of Go Kart therefore its material should contain high
strength and cost should be low. Keeping in mind all the factors and the forces
acting on the chassis we have we have selected three materials SAE 1018, AISI
1212 & AISI4130 and compared their mechanical and chemical properties. After
comparing we found that SAE 1018 and AISI 1212 where heavy in weight and
comparatively lower in strength than AISI 4130. AISI 4130 also clear the factor of
safety when normalized at 870 C
CHASSIS DESIGN

OUTER DIAMETER WALL THICKNESS


CHASSIS MEMBERS 1 INCH 1MM
BUMPER MEMEBERS 0.5 INCH 1MM

We Realised as OD for bumper parts in not mentioned in the IKR


Rulebook we decided to give smaller profile members but in
triangulation , the members are set in a way that each member
is under compression and tension when under load , this greatly
increases its load ability compared to a straight member with
larger OD and is 4200g lighter overall
BUMPERS WITH 1inch OD BUMPERS WITH 0.5inch OD BUT WITH EXTRA MEMBERS FOR TRIANGULATION

CHASSIS MEMBERS
While most go kart frames are made in a single 2D Plane our front supenstion members are
raised on which the kingpin is mounted , which is way stiffer and tortinally rigid then if we
would have joined on a bar from the chassis ,
This greatly increases chassis rigidity as the kingpin and the axle stud is directly connected
to the chassis and eliminates flex that would have been there if we would have mounted it
to a stalk from a chassis
, also it helps lower the center of the gravity
Driver safety

Different cases of impacts are calculated by the procedure as follows:


As the mass of our Go-kart is 205kg
And gravitational acceleration g = 9.81m/s2 .
We assume it approximately as 10 m/s2 .
Calculations: F = m x g F = 205 x 10 = 2050N
1) Front Impact Analysis As per standards we use 4G for front impact analysis.
2) Therefore, Total force = 4 x F = 4 x 2050 = N
The impacts are purely elastic collision
Formula Used: (Impulse momentum theorem – Newton’s 2nd law)
F=m×a
Factor of safety (FOS) = Yield stress / Working stress
Where, F – Impact force applied on the vehicle m – Mass of the vehicle (145+ 60 = 205 Kg)
Here we assumed our vehicle to experience the impact force at a speed of 60km/hr for a
collision time of 1.05secs in the front region of our frame by applying constraints at the rear
end.
Therefore, F = 205 × 4 ×9.8=8036 N
Total Deformation The 7573.32 N force is acting on the frontal member of the chassis and
constraint are given in rear side of the chassis. We get the result of following deformation,
via solidworks
The standard formula for finding the factor of safety is given below
v. F.O.S. = yield stress / working stress = 460 / 125.1 F.O.S. = 3.67
B. Rear Impact
1. Total Deformation The 7573.32 N force is acting on the rear member of the chassis and
constraint are given in front side of the chassis.
We get the result of following deformation, in solidworks .
Rear impact maximum deflection Maximum deflection = 10.47 mm.
2 Equivalent Von-MisesStress According to the rear impact force acting on the chassis the
following stresses are generated in Ansys.
Rear impact equivalent stress Maximum stress value = 343.7 MPa.
FOS = yield stress / working stress = 460 / 343.7 FOS = 1.33
Side Impact Analysis As per standards we use 2G for side impact analysis.
Therefore, Total force = 2 x F = 2 x 2050=4050N

Conclution
Chassis material AISI 4130

CHASSIS WEIGHT 12400g

Gross weight 145 kg + 60kg = 205kg

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