Density

7.87g/cc

Yield Strength

370 MPa

Poisons Ratio

0.29

Ultimate Strength

440 MPa

Modulus Of Elasticity

205 GPa

Element

Content

Carbon(C)

0.14-0.20%

Sulphur(S)

<=0.050%

Iron(Fe)

98.81-99.26%

Material

OD

inch

ID

inch

Bending

Strength

(Nm)

​

Stiffness

Weight/

meter (Kg)

Cost/

Kg

(₹)

AISI1018

1

0.874

240.93

1742.5

0.941

160/-

AISI4130

1

0.874

308.22

1742.5

0.939

360/-

AISI1018

1

0.842

286.29

2070.5

1.16

150/-

AISI1018

1.25

1.124

402.52

3540.35

1.192

160/-

AISI4130

1.25

1.124

498.39

3540.35

1.189

360/-

Type of frame

Space frame

Bends

5

Welds

80

Material length:

OD=1” ,ID=0.874”

OD=1.25” ,ID=1.124”

​

457.67 inch

350 inch

​

Chassis weight

17.65Kg

Type of impact

Load

Equivalent stress

Deformation

FOS

Front impact

10000N

( 6.06G)

195.45

2.1047

1.89

Rear impact

10000N

( 6.06G)

293.96

5.16

1.258

Side impact

5000N

( 3.03G)

282.48

5.716

1.309

Torsion test

4000N

( 2.42G)

355.91

14.273

1.0396

Solver

Frontal

Meshing method

Shell

Nodes

​

238649

​

Elements

​

124207

​

Impact time

0.2s

Total weight

165kg

speed

80Km/hr

Ergonomics

Angles

Hip angle

52

Knee angle

104

Ankle angle

82

Elbow angle

130

Vision Cone angle

45

Parameters

Values

Turning Radius

1.9m

Steering Ratio

1:1

Steering

Angle

Inside

Outside

38

24.3

Steering Wheel Radius

10”

Steering Wheel Torque

6.68Nm

Steering Stops

(centre To Lock)

0 -38

​

Tie Rod Length

342mm

Ackerman Percentage

102

Ackerman Angle

18

King Pin Inclination

8⁰

Caster Angle

5⁰

Camber Angle

-4⁰

Steering Effort

2.6kg/Hand

Column Inclination

60

Scrub Radius

75mm

Toe Angle

Toe in 2⁰

Stopping Distance

8.97 m at 75kmph

Pedal Force

200 N

Pedal Ratio

1:6

Weight Transfer

1036.28N

Coefficient Of Friction(road)

0.6

Static rolling radius

0.135m

Frictional Force

3306.67N

Clamping Force

8266.68N

Brake Torque

32655 Nm

Deceleration

24.18m/s2

Pressure Inside TMC

4.21 MPa

Brake Type

Hydraulic disc brakes

Master Cylinder Dia.

19.05mm

Calliper Cylinder

25mm

Brake Fluid

Dot 4

Speed

30Kmph

40Kmph

50Kmph

60Kmph

Stopping Distance

1.43m

2.5m

3.98m

5.73m

Front

10-4.5/5”

Rear

11-7.1/5”

Specification

Access

Vespa

Discover

Displacement

124cc

125cc

124.6

Max. Power

8.7Ps@ 7000 rpm

10.5Ps@ 7500rpm

11.5Ps@

8000rpm

Max. Torque

9.8Nm@5000

rpm

10.6N m @ 6000rpm

​

10.2Nm@6000rpm

Transmission

CVT

CVT

Geared

Shaft Material

Stainless Steel 402

Shaft Dia.

30 mm

Top speed

85Kmph

Acceleration

2.68m/s²

Performance

0-60kmph in 6.2sec

Maximum towing capacity

2250 kg

CVT Speed ratio

2.2:1 – 0.7:1

Gear reduction Speed ratio

7.57:1

Chain drive Speed ratio

0.8:1

Overall ratio

13.32:1 – 4.24:1

Equipment

Specification

Bench Drilling

Capacity 25mm

Radial Drilling

Capacity 35mm

Power Saw

Max dia 175mm

Arc Welding

O/P 60-160A

Tig/Mig Welding

O/P 250A

Milling Centre

Table size 1mx0.25m

Press Forging

2 Tonnes

Equipment

Specification

Center Lathe

Centre Distance -1.5m

CNC Turning

Max turning dia 250mm

CNC Machining

Max load 600Kg

Planar M/C

L=2.5m, w=1m

Shaping M/C

Stroke = 915mm

Cupola Furnace

Inner dia= 600mm

Bench Grinder

dia=0.3m,t=20mm

Processes Involved

Tool /Equipment Requirement

1.Welding

• MIG welding machine
• Arc welding machine
• Welding electrodes
• Wire spool
• Helmet
• Gloves

​

2.Drilling

• Drilling machine
• Drill bits

3.Grinding

• Grinding machine
• Grinding wheel

4.Cutting

• Hand cutter
• Cutting wheel

5.Bending

• Bending machine

Component

Function

Potential Failure Modes

Potential Failure Effects

S

​

Potential Failure

Causes

O

D

R

P

N

Preventive Measures

​

Action plan to lower RPN

S

O

​

D

​

R

P

N

Chassis

Provides base on which all other components are mounted

Breakage of structural frame ,Torsion of chassis

​

Leads to collapse of vehicle, driver safety is endangered

8

Improper welding, not analysing using software, drilling into chassis

5

​

​

​

2

80

Analysis, proper design, proper material selection, welding selection

3

2

2

12

Engine

Power unit of the vehicle

Improper lubrication, old spark plugs, improper fuel valve, overheating

Engine seizure, incomplete combustion, burnout of spark plugs, less mileage

8

Less lubricant volume, improper servicing of engine

6

3

144

Periodic service of engine, appropriate lubricant, proper cooling

4

2

3

24

Rear Axle

Transfer of power from engine to wheels

Improper material selection and overloading

Failure of transmission system, Breakdown

8

Fatigue/cyclic loading, improper dia. of shaft, improper mountings

7

3

168

Selection of material based on max load, choosing proper dia.

3

4

3

36

C-Clamp

For Proper positioning of knuckle

Shear of clamp bolts, breakage from chassis frame

Leads to total collapse of vehicle

10

Improper designing and mounting, improper welding

5

3

150

Providing ribs between chassis and c clamps for extra strength, load analysis

3

2

3

18

Brakes

To decrease the speed of a vehicle

Excess heat generation, cracks in rotor, expansion of brake fluid

Brake failure, brake fade, wheel locking

9

Improper selection of brake fluid, improper mounting of rotor

5

2

90

Thermal analysis of brake rotor, proper selection of brake fluid

2

4

20

16

Department/

Component

Test

Description

Acceptance Criteria

Test Stage

Date of

Implemen-tation

Test

Respons-ibility

Date of

Completi-on

Pass/

Not pass

Test

results

Notes or inference

Chassis

1. Frame

Impact test

Torsion test

Factor of safety > 1,

Driver safety

Analysis using ANSYS 15.0

30-05-2017

Deshik

1-06-2017

Pass

FOS

Impact

Front=

Side=

Rear=

Torsional=

Design is applicable for a gokarting vehicle

Steering

1.Tie rod

2.Steering column

3.Knuckle

​

• Geometry

Testing using simulation

• Knuckle analysis

​

​

Light weight, Proper assemblage,

Higher FOS,

Verification of Ackermann principle

Finite element Analysis using ANSYS 15.0,

Simulation using ADAMS,

2D diagrams in SOLID EDGE

2-06-2017

​

Kaustubh

4-06-2017

​

Pass

True rolling condition is achieved with

% of Ackermann principle

Driver is able to steer the vehicle with ease and comfort

Brakes

1.Disc Rotor

2.Rotor hub

• Thermal analysis
• Torsional analysis
• Stress analysis

Good heat flux rate,

Proper heat dissipation

Thermal analysis using ANSYS 15.0

​

Finite element analysis using

2-06-2017

​

Lokin

5-06-2017

​

Pass

Max. Temperature generated= ,

Heat flux= ,

FOS of Rotor=

​

Design of rotor hub is safe with higher FOS,

High thermal resistant rotor, Proper heat dissipation

Power train

1.Drive shaft

2.Chain drive

• Bending test
• Torsion test

​

​

Sustain light shock loads,

Safe design FOS, Better strength for tension loads

Theoretical calculations, Chain drive calculation using RENOLD Calculator

4-06-2017

Aditya

7-06-2017

​

Pass

The chain and sprockets and shafts are designed accordingly to the loads

The design withstands the loads

Power Transmission

Adithya M A

Vivek Gourav

Vijay Kumar

Akshay Achar

Vishnu Sharma

Architha Bhat

Chethan

Akash Acharya

Monisha

Purushotham Gowda

Chassis

Deshik K J(vice captain)

Nikhil M R(captain)

Sathwik U

Prasanna Kulkarni

Brakes

Lokin

Chandan Naik

Sandeep

Rafiq

Sonal Pal

Shantraj Kottur

Steering

Kaustubh

Ashish Wali

Ashish M

Himani Porwal

Prithviraj

Faculty Advisor

Dr G Mallesh

Associate Professor

Dept Of Mechanical Engineering

Sjce , Mysore

SL.NO

MATERIAL

COST

WEIGHT

1

Chassis

• Material
• Bumper and Mountings

Total

​

Rs 5000

Rs 1000

Rs 6000

​

17.65kg

5.75kg

23.4kg

2.

Brake

• Rotor
• Calliper
• Brake Pedal
• Hoses
• Master Cylinder
• Fluid

Total

​

Rs 1710

Rs 1500

Rs 500

Rs 400

Rs 985

Rs 180

Rs 5270

​

1.6kg

1.9kg

0.5kg

0.2kg

0.9kg

-----

5.1kg

3.

Steering

• C-clamp
• Column
• Knuckle
• Tie Rods
• SteeringWheel

Total

​

Rs 1745

Rs 745

Rs 745

Rs 1500

Rs 1400

Rs 6135

​

1kg

1kg

1kg

0.5kg

1.5kg

5kg

4.

Power Train

• Engine and components
• Shaft
• Bearing
• Sprocket and chain
• Hub
• Wheels

Total

​

Rs 30000

Rs 1800

Rs 1050

Rs 600

Rs 6300

Rs 12000

Rs 51750

​

38kg

6kg

3.2kg

2kg

2kg

8kg

59.2kg

5.

Miscellaneous

• Seat
• Bodywork,firewall,bellypan
• Fasteners

Total

​

Rs 1875

Rs 3500

Rs 500

Rs 5875

​

3kg

6.5kg

3kg

12.5kg

Sponsors

Rs 25000

College

Rs 20000

Team members

Rs 1400 each