1. TEAM TEAM ID: 141512 KIIT

2. STEERING TYPESTEERING KNUCKLE SYSTEM TURNING RADIUS 2.57m ACKERMANN ANGLE 25 0 PERFORMANCE Top Speed77 Kmph Acceleration3.24 m/s 2 0-60 kmph4.33 seconds GENERAL SPECIFICATIONS Body TypeAISI 1239B Cold Drawn Steel Kerb Weight~88kg Overall Length & width 70 inches & 46inches Wheelbase44 inches Track Width Front Rear 34 inches 40 inches Ground Clearance2.5 in. BRAKING TYPEHYDRAULIC DISC BRAKE STOPPING DISTANCE 4.2m PEDAL RATIO5:1 DISC SIZE200mm BRAKE OIL : Dot 3 or Dot 5 Poly-glycol based TRANSMISSION TypeManual Gearbox5 Speed Gear Box 1 down and 4 up Clutch Type multi-plate wet type

3. Design Objective: To Design, Analyze, Simulate & Manufacture small GO-Kart Vehicle in extremely low budget Material:-Minimum cross section must be 1 inch (25.4mm), for pipe it will be OD and for rectangular section or square section it will be its minimum height. Minimum Weight of the kart should be 60 kg. Dimension:-4 Wheels must not be in straight line in longitudinal direction.Wheel base Min 42 inches and smaller track of vehicle must be no less than 75% of wheelbase. Minimum 3 inches clearances(gap) between the driver and any component of the vehicle in static and dynamic condition. Ground Clearance must be at least 1 inches from static ground clearance. Wheel must be incorporated with axles with proper safety locking system. Steering:-Free play of steering system is limited to 7 ⁰ and stops must be used. Braking:-The brake system installed must be capable of stopping the vehicle in a straight line without losing control during the brake test. There should be no leakage from the tandem master cylinder (TMC) or reservoir. Engine:- 4 stroke single cylinder with total displacement of engine not exceeding 125cc per cycle. Jack Point- There must be 2 jack point (1 in front & 1 in the rear); Bumpers- Compulsory front & rear bumpers. Minimum OD 25.4mm and minimum wall thickness 1.65mm. Drivers seat -The seat mounting must be rigid enough to withstand the dynamic conditions while the driver is driving the vehicle on the track. The driver seat should be at least 3 inches away from the firewall. Brake Light:- The vehicle must be installed with a brake light red in colour which is clearly visible from the rear. Safety –Driver’s suit, underclothing, balaclava, neck support, gloves, shoes, socks, helmet, fire extinguisher, seat belt is necessary. A Firewall must be incorporated to separate the fuel tank from the driver. There should be min 3 inches clearance between the firewall and the engine. Capacity of the fuel tank must not exceed 8L in volume.The tank shall in no way be shaped to act as an aerodynamic device. Kill Switch-Minimum of 1 kill switch should be there to cut the power supply. Lock Nuts -use of lock nuts is mandatory. The driver egress should be less than 5 seconds. Exhaust System:-Use of suitable catalytic converter and the mufflers is recommended. Bolts:- All bolts used in the system must meet metric grade M8.8. Path for Wires and Pipes:- No pipelines/wire connections must go under the chassis.

4. SideForce in (N) Max combine stress in (mpa) FOSMax total Deformation in(mm) front4G1341.943mm rear4G1581.641.3mm side4G962.62.5mm torsional2G1411.841.4mm Fig 4:Torsion DeformationFig1:Front DeformationFig1.1:Front Stress Fig 2:Rear Deformation Fig 2.1:Rear Stress Fig 3:Side Deformation Fig 3.1: Side Stress Fig 4.1: Torsional Stress Design Methodology: * All Axle Points Should be at nodes. *There should not be any long continuous member to prevent bending. *No Square bar is used because of their high moment of inertia * Easy egress. * Keeping a driver alive during a 4G front impact, 4G Rear, 4G Side, 2G Torsional

5. METHODOLOGY:  Designed as per Rule Book.  Enough to accommodate 6 foot tall driver.  Easy entrance and exit for the driver.  Proper mountings for safety belt,steering, rear compartments for engine and transmission etc.  The ideal position for sitting at work exists when there is a slight curve in the lumbar region of the back  Proper positioning of steering wheel, making 80˚ elbow.  Proper positioning of seat and paddle assembly, making knees bent at 120˚ ideal for seating in Go Kart. EASE OF EGRESS: Driver should come out from vehicle within 5 seconds after pressing the kill switch. VISION & CONTROL: A minimum of 180˚ driver vision must be ensured.

6. Use of Ackermann geometry : This geometry stabilizes the vehicle while travelling around a curve with minimized scrubbing of the tires. Use of Steering Knuckle system: Most reliable, most robust and most controllable system for go karts. Simple Geometry and light weight. Easy to repair. Cheaper than other system of steering. PARTICULARSVALUE Inside wheel turning angle36 0 Outside wheel turning angle26.68 0 Ackermann angle25 0 Turning radius2.57 m Castor angle12 0 Kingpin Inclination Angle10 0 Toe in angle1010 Fig: Different parts of steering system. Methodology:  Because of lack of differential, a kart’s natural direction of travel, forward, is very difficult to change.  The inside wheel travels a shorter distance than the outside, therefore it needs to take fewer revolutions to go round the corner.  However, the two rear wheels are attached by a solid axle, and must therefore move together, so in order to turn, one of the wheels need to skid over the track surface.  This skidding action, or indeed the lack of it, is what make a stationary kart so difficult to turn round.  This is the reason for lifting the inside wheel and it effectively turns the kart into a tricycle during the cornering process.  The inside wheel can be lifted with proper selection of castor angle and kingpin inclination angle.

7. PARTICULARSVALUE TYPE OF BRAKE AND POSITIONDISC BRAKE AT REAR AXLE DYNAMIC WEIGHT TRANSFER51%-49% FRONT AXLE DYNAMIC WEIGHT(BOTH TIRES) 860.37N REAR AXLE DYNAMIC WEIGHT(BOTH TIRES) 807.323N REAR ROTOR BRAKING TORQUE94.104N-m PEDAL RATIO5:1 PEDAL EFFORT355.857N STOPPING DISTANCE(at 1.5g)4.2m BRAKE PEDAL MASTER CYLINDER BRAKE LININGS PISTON CALIPPERS VENTED ROTORS : Methodology: Disc plate must be mounted perfectly on the axle using circular plates and it also must be concentric on the axle. Caliper must be rigidly mounted to the stationary body or frame. The whole unit(plate and disc) is placed in the chuck of the lathe to check that the Disc is mounted concentrically. MC is bleeded before installing & is placed before pedal. Brake Linings are checked whether leak proof or not. : WHY DISC BRAKE: Reduced Maintenance / ease of installation Disc Brake calipers have only a few moving parts whereas drum brakes have many. Disc brakes has less joints and links as compared to Drum. Less sensitive towards corrosive conditions. Fast response, quick release, soft braking etc. The disc brake is less bulky and weighs less compared to the drum.

8. Engine SpecificationsValues Displacement125cc Engine Type4-Stroke Single Cylinder Max. Power11Bhp@ 8000 RPM Max. Torque11Nm@ 6500 RPM Cooling TypeAir Cooling Max Speed80 Kmph Compression Ratio9.2:1 Maximum Acceleration3.24 m/s 2 Why Manual Transmission? Significant reduction in cost. Light weight. Less uncovered parts to be taken care off. Reliable-uniform torque transmission in all respective gears GearReductionSpeed (kmph) 1 st 12.46:126.0 2 nd 7.88:141.2 3 rd 5.97:154.3 4 th 4.82:167.2 5 th 4.21:177.1 Final drive1.21:1 ENGINE 5 STAGE REDUCTION GEARBOX DRIVE SPROCKET CHAIN DRIVE REAR AXLE SPROCKET WHEELS Type of wheel: Belted deep radial groove tire with wider foot- print & air captive. METHODOLOGY  Odd number of teeth of sprocket in combination with even number of chain links facilitates uniform wear.  Accurate allignment of shafts and sprocket tooth faces provide uniform distribution of load across chain.  Incorrect mounting can cause problems from chain and drive to not be aligned causing express wear.  Use of mounting blocks with plates would be suitable.

9. College Facilities Manufacturing Lab Machine tools:- 1.Lathe machine 2.Welding shop 3.Grinding Shop 4.Shaping machine 5.Paint Shop 6.Carpentry shop 7.Bench Drill 8.Foundry Shop 9.Prototype Machine 10.CNC Hand tools:- 1.250 gm Hammer 2.Hand Files 3.Tong, Measuring Tools 4.Wire Brush 5.Cutting Tools 6.Drill Bits 7.Wrench sets Material Testing Lab 1.Universal Testing Machine 2.Impact Testing Machine 3.Brinell Hardness Tester 4.Rockwell Hardness Tester Software Lab 1.CAD/CAE 2.CATIA v5 3.SOLID WORKS 4.ANSYS 5.ADAMS 6.LOTUS Automobile lab 1.Wheel alignment machine 2.Tyre changing machine 3.Air Compressor 4.Impact Wrench Tools 5.Screw Jacks 6.Machine Dynamics Lab 7.Wheel Balancing Outside Facilities 1.FRP Molding 2.Hydraulic Press Fit 3.Emission Test Equipment

11. Team Captain – Ajit Pandey Vice Captain – Bishnu Pratap Singh Design Snehasis Pattanaik Chandan Kumar Transmission Kishore Ratan Jojowar Nischal Nishant Shanker Manasi Deshpande Steering Nikhil Nirupam Saurav Prakash Satyam Singh Fabrication Nirmal Singh All team members Brakes Ankit Kumar Gupta Shubham Chowdhury Rohan Maharana Ashutosh Safety & Electrical Bishnu Pratap Singh Material Procurement Prateek Jha Joy Banerjee Documentation Manasi Deshpande Wheels Shivani choudhary Aadrika Borah Ghanshyam Singh Sanidhya Kumar Faculty Advisor – Prof. I. Panigrahi

13.  Nut Loosening & Detection System Simple mechanism of close and open circuit using battery and led light. During Endurance race it Can avoid serious injury to driver caused due to failure of parts.  TYRE PUNCTURE DETECTION : Principle: A small pressure gauge transducers are fitted on tires valves, when tires is at optimum psi the needle moves away from alarm switch, but when pressure decreases the needle comes in contact with alarm system and starts detecting. * The alarm switch is placed inside the pressure gauge. * The alarm switch is connected to the positive terminal of the battery & needle of transducer is connected to negative terminal of battery. Battery