Design and Fabrication & Performance Analysis of Low Speed Recreational Vehicle

Abstract

A go-kart is defined as a light, four-wheeled vehicle commonly employed for recreational purposes or motorsports at the amateur level. Based on the simple design and lack of complex suspension systems, the go-kart is considered an ideal tool for grasping elementary mechanical engineering principles like vehicle mechanics, structural analysis, and power transmission mechanisms. This project is centred on the design, analysis, and construction of a go-kart that is safe, economically viable, long-lasting, and energy-efficient. The chassis, which is the structural foundation of the go-kart, is designed utilizing materials like AISI 4130 or mild steel for adequate strength, stiffness, and weight optimization. Structural analysis is performed on the go-kart to determine the distribution of stresses, deformation, and factor of safety under different operating conditions like frontal, rear, and lateral impacts. Finally, the design is optimized for an optimal balance between performance, safety, and economic viability. Keywords: Go-kart, chassis design, AISI 4130, mild steel, structural analysis, stress distribution, deformation, factor of safety, vehicle dynamics, power transmission, braking system, fabrication, safety, performance, cost-effectiveness.

Introduction

The text describes the design, analysis, fabrication, and testing of a go-kart aimed at achieving safety, efficiency, durability, and cost-effectiveness. A go-kart is a lightweight four-wheeled vehicle commonly used for recreation and beginner motorsports, making it suitable for studying mechanical engineering concepts such as chassis design, vehicle dynamics, braking, and power transmission.

The project primarily focuses on developing a strong and stable chassis with proper weight distribution and structural integrity. Key objectives include maintaining a balance between performance, safety, and manufacturing cost.

The literature survey reviews previous research on go-kart chassis design and analysis:

• Researchers emphasized robust and low-cost chassis designs using triangulation for better rigidity and driver safety.
• CAD tools like SOLIDWORKS and ANSYS were widely used for 3D modeling and structural analysis.
• Materials such as AISI 1018, AISI 4130, and mild steel were identified as suitable due to their strength and lightweight properties.

The methodology follows several stages:

1. Design Requirements – considering safety, strength, ergonomics, weight, and cost.
2. Conceptual Design – deciding chassis layout and component placement.
3. CAD Modeling – creating a 3D chassis model using SOLIDWORKS.
4. Material Selection – choosing materials based on strength, stiffness, and weldability.
5. Structural Analysis – analyzing the chassis in ANSYS under front, rear, and side impact conditions.
6. Fabrication and Testing – manufacturing the chassis using cutting, bending, and welding, followed by inspection and performance testing.

The chassis design uses tubular members arranged with triangulation to improve rigidity while keeping the structure lightweight. A low center of gravity improves stability and handling.

The results show that the fabricated go-kart successfully meets safety and performance requirements. Structural analysis confirmed acceptable stress levels, minimal deformation, and a sufficient factor of safety. Testing demonstrated stable handling, effective braking, and reliable operation.

Key observations include:

• Proper weight distribution improves control and stability.
• A low center of gravity enhances cornering and handling.
• Triangulated chassis design increases strength and rigidity.

Conclusion

The go-kart was successfully designed, analysis, and fabricated to meet the objectives of safety, performance, and cost-effectiveness. The chassis design ensures adequate strength, rigidity, and stability under various loading conditions. Analysis and testing confirm that the vehicle performs reliably with a satisfactory factor of safety.

References

[1] “Design and Fabrication of Race Spec Go-Kart” by Simranjeet Singh, Aniket Badgujar, Pushparaj Patil, Gaurang Kadam of Rajendra Mane College Of Engineering And Technology, India . [2] “Design Report of a Go-kart vehicle” by Shaik Himam Saheb, Govardhan Reddy, Md. Hameed, Department of Mechanical Engineering, Guru Nanak Institute of Technology, Hyderabad, India. [3] “Fabrication of a Model Go-Kart (With Low Cost)” by Dr.D.Ravikanth, C.Nagaraja, Dr.K.Rajagopal, Dr.V.S.S.Murthy, Department of M.E.D, K.S.R.M.C.E,KADAPA/ J.N.T.U.A.University, Anantapur, India. [4] “A Review Paper on Design and Analysis of a Go-Kart Chassis” by Koustubh Hajare, Yuvraj Shet, Ankush Khot, Mechanical Department, D.K.T.E Institute, India. [5] “Design and analysis of go-kart chassis” by Mr. Virendra. S. Pattanshetti , Department Of Mechanical Engineering, DKTE’s Textile and Engineering Institute Ichalkaranji, India. [6] “Design and Analysis of Go-Kart Chassis” by Ujjal Kalita, Yenduru Surya Teja, Darisi Sri Veera Venkata Manikanta, Mechanical Engineering, Lovely Professional University, Jalandhar, Punjab, India.

Copyright

Copyright © 2026 Dr. Akshay Anjikar, Shashank Deshbhratar, Chinmay Kamble, Atharva Mogare, Sahil Jagtap. 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.