An Industrial Internship Training Report

Done by

Rutuja Jagan Gangurde

(Team Spartans)

Tushar Kumbharde (Team Mentor)

At

Go Kart Event

Submitted to

Department of Mechanical Engineering

Faculty of Engineering & Technology

SNJB KBJ COE. Neminagar,

College of Engineering

Chandwad, Maharashtra 423101

February 2023

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 Acknowledgement
It is a great pleasure to us in acknowledging our deep sense of gratitude to all those who
have helped us in completing this project successfully.

First of all, we would like to thank University of Pune for providing us an opportunity to
undertake a project as a partial fulfillment of engineering degree. Special thanks to Prof. D. D.
Sancheti Sir for providing us an opportunity to work with Team Spartans and providing us
necessary information about their Team, their operations and providing guidance in developing
our project.

We would have not completed our project without the help and co-operation of certain
people.

Acknowledge our sincere thanks to Prof. D.D.Sancheti Sir for Their guidance that made us
materialize this Project.

Finally, I am also thankful to my parents and friends for their encouragement and
support. I would like to thank Prof S.D Sancheti Sir (Head of Mechanical Department) and Dr.
R.G Tathed Sir, (Principal) for the guidance and support they have provided during the project.

Rutuja Jagan Gangurde

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 INDEX
Sr no. Content Page no.

1. Cover page 1

2. Certificate 2

3. Acknowledgement 3

4. List of Content 4

5. Abstract 5

6. Team Structure 6

7. About Design 7

8. Chassis 7

9. Engine 8

10. Steering System 9

11. Breaking System 10

12. Transmission System 11

13. Selection of Chain & sprocket 11

14. Keys 11

15. Wheels & Tires 11

16. Driver seat 12

17. College Facilities 12

18. Conclusions 12

19. References 12

5. Abstract
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 Team Spartans aims at designing and fabricating ago – kart which has high speed
and a good fuel economy with safety and entertainment in driving. The CAD model in CATIA
V5 R20 and analyzed in ANSYS Workbench 14.5.

The vehicle is required to have a chassis consisting of steel members. This paper highlights the
design and analysis of the Go-Kart chassis and other sub-systems. It will cover the design
constraints given by Authority. Material selection, initial design, and structural analysis. It will
finally cover the results of the vehicle simulations.

Club Name: Team the Spartans

SNJB's late Sau K.B. Jain College

Of Engineering Chandwad (Nashik)

423101

Internship Mentor Details:

Name: Tushar Kumbharde

(Mechanical Engineer)

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6. Team Structure
Everything in life begins with hope. Hope backed by effort is what made “THE
SPARTANS” tangible. The Spartans is a coalition of all our endeavours and uphill battles. It is
the shape given by efforts of the students from Department of Mechanical Engineering,
SNJB’s Late Sau. K B. Jain College of Engineering, Chandwad who thought to
fabricate a vehicle in college campus situated at very isolated place. Team Spartans began the
task of designing by doing a lot of research and by conducting experiments of each and
every component that is possible.

It also integrates the use of standard part which also reduces the manufacturing cost of the
vehicle. Combining these design with standard engineering design, design process is enabled us
to achieve a perfect match of aesthetics, performance and ease of operation and is made
efficient.

Providing all the necessary information for developing a good system. We would not
forget to Remember Prof. R. G. Tathed Sir, Principal of SNJB’s Late Sau KBJ College of
Engineering Chandwad.

Parameters Values

Length 76 inches

Width 41 inches

Wheelbase 44 inches

Track width 35.5 Inches

Ground clearance 1.5 Inches

Kerb weight 96.7 Kg

Front tyre 10 × 4.5 -5

Rear tyre 11 × 6.5 -5

Max. speed 69.18 Km/hr.

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7. About Design

8. Chassis
Based on the overall design objectives of durability, performance and lightweight design, the
component is evaluated by the design team and meet all of the criteria to become a part of the
overall successful design.

1. Cross Section of Pipe: 25.4mm x 2 mm

2. Wheel Base: 44 Inches.
3. Front Track Width: 36.5 Inches.
4. Rear Track Width: 36 Inches.
5. Total Members: 8

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 6. Total Weight of Chassis (with mountings):
13.770 Kilograms
7. Total welds: 14
8. Designed Ground Clearance: 1.5 Inches.
Weight Distribution of our Vehicle is estimated at 60:40 (Rear: Front) for:

1. Proper Stability to Vehicle.

2. Perfect Cornering.
3. Attaining high speeds as quick as possible.

Selection Process

9. Engine
As per the international standards a Go – Kart is generally 125cc and the criteria is of
135cc itself. An engine of a GO - Kart is usually a small one and according to the rule we have
selected engine of about 125cc, 4-stroke, Petrol Engine, which produces about 11BHP@8000
RPM. We have firstly compared between two of the best engines between Honda Stunner CBF
125 and Honda Stunner 125, finally we had selected Honda Stunner 125 engine due to its proper
fulfillment in our requirement.

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 The reason behind our decision for selecting the Honda Stunner 125 engine is that, after
comparing various engines we observed that Hero Igniter’s engine is somewhat more powerful
than the fuel efficient Hero Igniters 125. Also the time required for attaining the speed from 0
kmph to 50 kmph is about 5 seconds which is a great advantage. Also depending upon the
reviews given by the customers who have already used the same vehicle, we then finally selected
Honda Stunner CBF 125 engine.

10.Steering System
There are various types of Steering systems available in market, but only the best suited steering
is need to be used. Nowadays Power Steering is used widely due to low force to turning ratio. Kart racing
we need a low response timing steering so that driver will not get fatigue. For Go – Kart we have to
equipped with quick response and highly actuating steering system.

Validation of steering system

We have calculated the Turning Ratio for our Steering System and it is found out as per
the following steps. Step 1: We have first measured the turning angle of our outer wheels. It was
measured as 30 ˚. Step 2: Then we have measured the turning angle of Steering wheel. It was
measured as 25 ˚.Other details regarding Steering System is given below:

1. Steering Geometry: Ackerman

2. Turning Radius: 1.5m
3. Steering Ratio: 1:1.2
4. Tie Rod Length: 300.2 mm
5. Steering Arm Length: 76.20 mm
6. Steering Wheel Diameter: 254 mm
7. King Pin Inclination: 14 ˚
8. Camber: 1 ˚
9. Caster: 7 ˚

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 11. BRAKING SYSTEM

The Braking System has to provide enough braking force to completely lock the
wheels at the end of a specified acceleration run, it also proved to be cost effective. The braking
system was designed by determining parameters necessary to produce a given deceleration and
comparing to the deceleration that a known braking system would produce. The best of the
braking solutions, a disc brake is a high tech advancement in go karting. They provide superior
stopping power, even when it is wet and most importantly it is noiseless, but after some passage
of time they too provide noise. Kart is equipped with hydraulic disc brake with braking fluid
DOT-3 which is a polyethylene glycol based fluid. In a normal passenger cars this selection of
fluid is not a major issue but it is serious concern in race cars.

1. Solid shaft diameter = 30 mm

2. Brake fluid = DOT 3
3. Disc outer diameter = 160 mm
4. Disc inner radius = 45mm
5. Master cylinder diameter =10mm = 0.01m
6. Caliper piston diameter = 25.4mm
7. Brake pedal leaver ratio = 4:1
8. Transmission efficiency 80% = 0.8
9. Normal force applied on pedal = 126.71N.

The Abbreviations used are as follows: W = Gross weight of the kart P = Brake liner
pressure C.F = Clamping force R.F = Rotating force B.T = Braking torque B.F = Braking
force a = Deceleration S.D = Stopping distance R.E = Effective disc radius

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12. TRANSMISSION SYSTEM

Designing the Shaft diameter is the most important method as shaft is subjected to
both Twisting and Bending Moment. Therefore consideration of both the moments is
important and the shaft or rear axle on which various mountings are done should be
considered. Gear Reduction Ratios are as follows:

1st Gear ratio: 3.076

2nd Gear ratio: 1.944

3rd Gear ratio: 1.473

4th Gear ratio: 1.19

Primary Gear ratio: 3.35

Final Reduction ratio: 3.071

The determination of diameter of shaft is done using A.S.M.E Code (American Society of
Mechanical Engineers). It is one of the approaches followed in design of transmission
shaft.

13. SELECTION OF CHAIN AND SPROCKET

Chain and Sprocket is used to ensure that the chains do not get loosen with the
passage of time and did not get slipped off quickly. It should be properly lubricated and
maintained so that the chain will have a long life and ensures safety of the driver. The
speed of vehicle is mainly dependent on the design and selection on Number of Teeth’s
on Sprockets and Length and type of the chain but mainly Roller type of Chain is
preferred as it has less maintenance and is easy to assemble and disassemble as per the
requirement. Optimal Engine RPM: 2700 RPM

14. DESIGN OF KEYS

For our application we are using Square Key manufactured using material C50 having
chemical composition of 0.50% Carbon and 0.60 to 0.90% Manganese. Tensile Strength
of 700MPa, Ultimate tensile stress of 320 MPa and Brinell hardness of 241 BHN.

15.WHEELS AND TIRES:

Tires should be 4.5” internal diameter. The maximum exterior diameter of the front
wheels is 10” and that of the rear wheel is 11”. The maximum width of the rear wheel is
7.10” and the maximum width of the front wheels is 4.5”. The Front tires specification is
10 × 4.5-5 and that of the rear tires is 11× 7.10-5.

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16. DRIVER SEAT

Ever Go Karting seats should be comfortable so that the driver will be able to adjust
himself. The seat in this kart is also designed to be very light it is very simple made up of
plastic material and is attached to the chassis by four points and a comfortable back side
angle of the seat. The seat mounting must be rigid enough to withstand the dynamic
conditions during the track events. The driver seat should be well cushioned and at least 3
inches away from away from the firewall. Alignment of the driver seat/driver sitting
direction must be parallel to vehicles longitudinal axis or somewhat slightly inclined.

17. COLLEGE FACILITIES

All the team members used the machines for the job and maintain proper discipline and
also followed our college rules. The Facilities provided by our college for manufacturing
the vehicle is listed below:

1. CAD Lab
2. Lathe Machine
3. Milling Machine
4. Drilling Machine
5. Grinding Machine
6. Hydraulic Powered Hacksaw
7. Welding Machine
8. Bending Machine
9. Portable Rivet Machine
10. All instruments that is required for Assembling and Disassembling the Components
like Spanners, Pliers, Bench Vice and Portable Machines.
18. CONCLUSION

Our objective of designing and developing a go-kart seems to be accomplished within the
time period estimated. The design process included CATIA V5 R20 and ANSYS
software packages to model, simulate and analysis of the complete vehicle. This design is
based on the provided rulebook. The design and fabrication of the go-kart focused on
developing a simple, lightweight and easily operated vehicle.

19. REFERENCES
 R.S. Khurmi & J.K.Gupta, machine design, first edition, 2005 Eurasia
publication house (pvt.) ltd.
 Automobile Engineering- Dr.Kirpal Singh
 Design of Machine Element- V.B.Bhandari and Strength of Material- R.k.Raj

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