PROJECT 1: GO-KART DESIGN Car manufacturing requires a lot of engineering minds, man power and powerful management. A kart can be considered a small unit as compared to the any other car but still manufacturing it can be a headache. Designing is the first step before manufacturing by which we can see what our product might look like. If required, one can change the design for better possibilities. Designing of Go-kart in any software require knowledge about software in which you are going to design your Go-kart. I ve used CATIA V5 R20 for my Go-kart designing. Making this design is not a one night show but require so many days work. I ve divided my work for different days i.e. tyre with hub and frame, chassis, engine, steering system, gear, tubes with pedals, axle, clamps etc. Simple steps are there for making any parts i.e. part design, selecting the plane, sketcher, draw the one view of the part, exit workbench, pad and filling its dimension, apply material and then ok. After making all the parts, assembly is done by assembly design option in Catia. By using command existing component, each part is selected one by one, manipulated and placed on its respective place. 1st day: - wheel making. Rear wheel consist of three parts- tyre of rubber, frame and hub of steel material. Tyre and its frame is not a very big task but making a hub is a big thing. So I ve made this hub. Fig 1:hub
Fig 2: Tyre frame Fig 3: tyre After assembling of all the three parts, full rear wheel looks like:- Fig 4: real wheel
2nd day is for front wheels. Front wheel consists of three parts- tyre, frame and a hub. I ve used same tyre and frame from rear wheel setup. But the hub is of simple type i.e, an iron thick plate with a hole at the Centre. Fig 5: Front wheel with tyre, hub and the frame 3 rd day is for skeleton making of the kart i.e. chassis. Generally kart making industry uses hollow pipe for making the chassis but I ve used hollow rectangular bar of different dimensions- 1. Middle bar is of 3 X 1.5 in in which full load is going to act and 2. Rest of the hollow bar of dimension 1.5X1.5 in. Fig 6: Chassis
Petishell, c-clamp and spindle for 4th day Petishell is a part which is bolted with the chassis in which the axle is placed with the tyre which provide the support to the chassis. It is only used at the rear part. Fig 7: Petishell C-clamp is a part which is welded with the chassis in which a lot of engineering work is required for castor and camber angle of steering geometry. Fig 8: C-clamp Spindle is a part which is screwed with the c-clamp which accounts for the motion of the front wheel while taking turns. Angle between Spindle arms with axle is 104 degree.
Fig 9: spindle Engine is just a model that looks like an ordinary engine. Just because we are making a model of kart so it is not necessary to make each and every part of the engine. Fig 10: engine Seat is a part which is made according to the comfort of the driver. Gear is another part which comes under engine parts. Gear is of two types small is of 14 teeth and big one is of 34 teeth. Fig 11: Small gear fig 12: big gear Both engine and both the gear was done on 5 th and 6 th day
7 th day -Steering system GO-KART DESIGN RAJENDER SINGH Steering system consists of steering plate, steering arm(tie rod), steering wheel and steering rod. All these parts are made separately and then assembled together to form steering system. Fig 13:-Steering system 8 th day: - Final assembly. After designing all the parts, embossment is done by selecting the plane and drawing each embossment with a particular shape and size or we can make it a separate part. And then assemble later. Fig 13: embossment
A person can be introduced into the assembly design by the help of ergonomics design and analysis option. The posture of person can be changed by the human posture option present in the ergonomics design and analysis. Fig 15: wire frame diagram Actual manufactured kart based on this design looks like:- Fig 14: go-kart
This go kart can be further modified by introducing the cover on it for better look and safety of the rider like bat mobile.