Design and Analysis of a Go-Kart

Abstract

This research paper presents the structural design and analysis of a go-kart vehicle intended for competitiveracingapplications.Thedesignintegratesconsiderationsforsafety,ergonomics, cost-efficiency, and structural integrity. The chassis and critical components such as the knuckle, disc, and wheel hub were modeled using CAD software and analyzed via finite element analysis (FEA) in ANSYS. Various impact scenarios such as front, rear, side, torsional, and vibrational (modal) were simulated. The results validated the design\'s safety margins under the intended loads and conditions.

Introduction

This study focuses on designing a lightweight, structurally robust, and ergonomic go-kart. The design emphasizes optimal weight distribution, safety under various impact conditions, effective thermal management in the braking system, and driver comfort. The chassis was modeled in SOLIDWORKS and analyzed using ANSYS simulations.

Material Selection:
AISI 4130 steel was chosen for the chassis due to its high strength-to-weight ratio, toughness, and weldability. Other components used materials like GSM mild steel and stainless steel based on their mechanical properties.

Methodology:
The chassis was treated as a space frame and subjected to simulations for front, rear, side, torsional impacts, and vibrational analysis. Similar structural analyses were performed on knuckles, brake discs, and wheel hubs.

Results:

• The chassis demonstrated adequate safety with factors of safety (FOS) ranging from 1.23 to 6.12 across impact types.

• Knuckles experienced a maximum stress of 456 MPa under lateral turning forces.

• Brake discs reached peak temperatures of 315.7°C during braking with minimal stress.

• Wheel hubs showed low stress and negligible deformation under applied moments.

Conclusion

The designed go-kart chassis and components demonstrated safe operational limits undersimulated impact, thermal, and mechanical loads. Finite element analysis provided valuable insights enablingdesignoptimization.Thefinalmodelislighter,structurallysound,andergonomicallyrefined for competitive performance.

References

[1] Milliken & Milliken, Race Car Vehicle Dynamics [2] Mirone, G. (2003). MultibodyModelisation of a Go-Kart with Flexible Frame. [3] Prof. Lingiah, Design Data Handbook Vol I and II [4] Kripal Singh, Automobile Engineering [5] R.S. Khurmi, Machine Design [6] Shigley, Machine Design [7] Thomas Gillespie, Vehicle Dynamics

Copyright

Copyright © 2025 Prof. M. S. Shelke , Yash. C. Shendre. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.