International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 6, June 2017, pp. 305 311, Article ID: IJMET_08_06_031 Available online at http://www.ia aeme.com/ijmet/issues.asp?jtype=ijmet&vtyp pe=8&itype=6 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication Scopus Indexed MODELLING AND STRUCTURAL ANALYSIS OF A GO-KART VEHICLE CHASSIS FRAME K. Chinnamaddaiah MLR Institute of Technology, Hyderabad, India Y. Lakshmipathi MLR Institute of Technology, Hyderabad, India P. Ravikanth Raju Anurag Group of Institutions, Telangana, India Subramanyam B MLR Institute of Technology, Hyderabad, India ABSTRACT Transportation, both public and private, has become an important part of our dayin consumption to-day life. Its usage has increased enormously leading to an increase of fuels. Global warming at this junction seems to be elevating rapidly. However, due to the increased consumption of fuels and the depleting resources, there will be non- availability of fossil fuels in the coming future. The present scenario in automotive industry is an sum in demand of trucks not only on the cost and heaviness aspects but too on improved total vehicle features and overall work performance. The chassis plays an important role in the design of any automobile vehicles. Chassis is the structural backbone of any vehicle. The main function of Automobile chassis is to carry the goods and payload placed upon it. The chassis frame has to bear the stresses developed and deformation occurs in it and that should be within a limit. This paper presents the study of the stress developed in chassis as well as deformation of chassis frame. The stress and deformation has been calculated for the chassiss frame and the analysis has been done for the validation on the chassis frame. The model of the chassis has been developedd in CATIA v5 and Impact analysis has been done in ANSYS WORKBENCH 15.0. Key words: Chassis, Chassis loads, Modeling, Structural analysis. http://www.iaeme.com/ijmet/index.asp 305 editor@iaeme.com
Modelling and Structural Analysis of a Go-Kart Vehicle Chassis Frame Cite this Article: K. Chinnamaddaiah, Y. Lakshmipathi, P. Ravikanth Raju and Subramanyam B. Modelling and Structural Analysis of a Go-Kart Vehicle Chassis Frame. International Journal of Mechanical Engineering and Technology, 8(6), 2017, pp. 305 311. http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=6 1. INTRODUCTION Chassis should be rigid enough to withstand the shock, twist, vibration and other stresses. Along the strength, an important consideration is chassis design is to have adequate bending and torsion stiffness for better handling characteristics. The chassis frame has to bear the stresses developed and deformation occurs in it and that should be within a limit. So, strength and stiffness are two important criteria for the design of chassis. The load carrying structure is the chassis, so the chassis has to be designed that it has to withstand the loads that are coming over it. The objective of this work is to find out best material and most suitable cross-section and deflection of the chassis under maximum load condition. The problem to be dealt with this work is to Design and Analyze using suitable CAE software for ladder chassis.. In India number of passengers travel in the bus is not uniform, excess passengers are travelling in the buses daily due to which there are always possibilities of being failure/fracture in the chassis/frame. Therefore Chassis with high strength cross section is needed to minimize the failures including factor of safety in design. So the Rectangular box type cross section has taken for making ladder chassis by analyzing in F1 car. Henceforth, the main objective of this paper is to analyze which is a small F-1 type race car, serving the above mentioned purpose. The chassis is designed by taking the constraints of the automobile components to reduce the overall weight. The result improved payload for improved productivity and fuel-efficiency. 2. DESIGN OF A LADDER TYPE CHASSIS Chassis is the backbone of any vehicle. It is designed to bear all types of load whether long duration, short duration or impact load. It contains mounting space and points for all the component of the vehicle. The chassis should have proper stiffness to weight ratio for better performance of the vehicle and also ergonomics should not be sacrificed in order to achieve it. It should be able accompany 85 percentage. Most important one it should obey the rule book. Before finalizing the chassis a 1:1 PVC model was made and ergonomics test was carried out. Proper observations were taken and alterations were made in chassis design according to requirements. The drafted views, Isometric views of the chassis as shown in figure 1 and figure 2. 3. MATERIAL SELECTION AND MATERIAL PROPERTIES Young s modulus (E) =215 GPa Yield strength =800 MPa Poisons ratio = 0.285 Density =7800 kg/m 3 http://www.iaeme.com/ijmet/index.asp 306 editor@iaeme.com
K. Chinnamaddaiah, Y. Lakshmipathi, P. Ravikanth Raju and Subramanyam B 4. LOAD CALCULATIONS The load calculations are carried out under static loading condition. Static Loading (Vertical Bending) Acceleration due to gravity= 9.81 m/s 2 Weight of chassis = 40 kg, Driver = 70 kg, Engine = 35 kg, Motor = 10 kg, Battery = 40 kg Each of its mass is given in its place. Therefore the total vertical static force including gravitational F= m x 9.81 Front Impact (Horizontal Displacement) = (2 1)/ Here, v2 = 0; (since, it is assumed that after impact it will come to rest) = 1/ (Here negative sign indicates that direction of impact force will be approx. to the velocity.) Neglecting the negative sign, =1/ The time t can be written as =2/ + Here v=0 and u=v1, Therefore, F=2/2 M = 250 kg, u = 60 km/hr = 16.67m/s, x = 0.5 F=69472.2 N Rear Impact (Horizontal Deflection) Force, = (2 1)/ Assuming that after back impact velocity gets 1.5 times more, therefore 2=3/2 1 =1/2 Assuming that vehicle moves distance x during this change, therefore time taken to cover this distance x, = 2/(+) =2/(2.5) F = (5/8)X(2/) M = 250 kg, u = 60 km/hr = 16.67m/s x = 1.5 m F=28946.76 http://www.iaeme.com/ijmet/index.asp 307 editor@iaeme.com
Modelling and Structural Analysis of a Go-Kart Vehicle Chassis Frame Side Impact (Horizontal Displacement) For side impact, model of vehicle is considered as a point mass (i.e. having same mass concentrated at one point. The side collision of vehicle is modeled as a perfectly inelastic one and necessary calculations have been carried out using conservation of energy and conservation of momentum principle. Velocity before impact V1= 60 km/hr = 16.67 m/s Velocity after impact V2 =0 [Here it is assumed that velocity vector after impact turned through an angle of 45 ] F=2/2 M = 250 kg, u = 60 km/hr = 16.67m/s, x = 0.5m F=69472.2 N 5. STATIC STRUCTURE ANLSYS OF LADDER TYPE CHASSIS First chassis is designed by considering the all ergonomics mounting points and all necessary design calculations. Then the chassis is modeled in CATIA V5 R 20 software. The model then converted into IGES format the analysis is carried out in ANSYS 14.5 WORKBENCH by importing the chassis in IGES format then all the material properties, boundary conditions and all calculated loads are taken and different types of analysis. Based on Load Estimation As per standards of FSAEcar parts are designed to withstand lateral forces the total mass of car components and drivers are listed in table.1 Chassis Rear Analysis If the total mass is 208 Kg the back side deformation of the chassis as shown in fig.3 If the total mass is 218 Kg the back side deformation of the chassis as shown in fig.4 If the total mass is 238 Kg the back side deformation of the chassis as shown in fig.5 If the total mass is 258 Kg the back side deformation of the chassis as shown in fig.6 Chassis Front Analysis If the total mass is 208 Kg the front side deformation of the chassis as shown in fig.7 If the total mass is 218 Kg the front side deformation of the chassis as shown in fig.8 If the total mass is 238 Kg the front side deformation of the chassis as shown in fig.9 If the total mass is 258 Kg the front side deformation of the chassis as shown in fig.10 http://www.iaeme.com/ijmet/index.asp 308 editor@iaeme.com
K. Chinnamaddaiah, Y. Lakshmipathi, P. Ravikanth Raju and Subramanyam B 6. FIGURES AND TABLES Figure 1 Drafted views of chassis Figure 2 Isometric view of chassis Figure 3 Back side deformation of chassis under 208 Kg of mass. Figure 4 Back side deformation of chassis under 218 Kg of mass. http://www.iaeme.com/ijmet/index.asp 309 editor@iaeme.com
Modelling and Structural Analysis of a Go-Kart Vehicle Chassis Frame Figure 5 Back side deformation of chassis under 238 Kg of mass. Figure 6 Back side deformation of chassis under 258 Kg of mass. Figure 7 Front side deformation of chassis under 208 Kg of mass. Figure 8 Front side deformation of chassis under 218 Kg of mass. Figure 9 Front side deformation of chassis under 238 Kg of mass. Figure 10 Front side deformation of chassis under 258 Kg of mass. http://www.iaeme.com/ijmet/index.asp 310 editor@iaeme.com
K. Chinnamaddaiah, Y. Lakshmipathi, P. Ravikanth Raju and Subramanyam B Table 1 Load estimation of structural analysis S.NO COMPONENTS MASS(KG) 1 Driver 50 2 Engine 80 3 Drive-train 20 4 Steering 12 5 Battery 05 6 Chassis 31 Total mass(kg) 208 7. CONCLUSIONS The chassis frame component has been modeled using CATIA V5 and analyzed in ANSYS workbench 15.0. The various parameters such as nodal displacement, stress distribution are completely analyzed and studied. The study shows that the area where the stress concentration is high due to applied load and the portions that have to be considered in the design of chassis frame in order to avoid frequent failures to improve its reliability. Stress analysis of chassis has been done to predict the weak points. Several state of the art papers and even books on chassis stress analysis have been presented in the recent years. This study makes a case for further investigation on the design of truck chassis using ANSYS software. The manufacturing methods are succeeded to the assembly of all the manufacturing components for the steering components of a race car. The numerical and simulated values of the pre study and analysis of all the components are satisfied and withstander the manufacturing requirements. REFERENCES [1] Subramanyam.B, P.Bridjesh, Design and Analysis of Student Formula Car Roll Cage, Indian Journal of Science and Technology, Volume(48). [2] DOI:10.17485/ijst/2016/v9i48/105996, December 2016. [3] Rushikesh D. Savan, Shekhar Y. Gajjal, Finite Element Modelling and Analysis of Brake Squeal, International Journal of Research and Scientific Innovation, Volume I Issue VIII. [4] Robertson, Dennis, and George J. Delagrammatikas. The suspension system of the 2009 cooper union FSAE vehicle: A comprehensive design review. No. 2010-01-0311. SAE Technical Paper, 2010. [5] V. B. Bhandari Design of Machine Elements McGraw Hill Education India Pvt. Ltd., vol. 3, 11th Edition, 20. [6] Fui, T.H., Rahman, R.A., Statics And Dynamics Structural Analysis Of A 4.5 Ton Structuralanalysis, Journal Mechanical, 24, 56-67, 2007. [7] K. Someswara Rao, K. Pradeep Kumar, B. Sai Kumar, D. Suseel and R. Hari Krishnan, Design and Analysis of Light Weighted Chassis. International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 96 103. [8] K Someswara Rao, M Pradeep Kumar, S Satya Prasad, B Siva Teja and Y Veera Sai Chandh, Design of Chassis of Two-Wheeled Electrical Vehicle by Optimization of Design Parameters Using Taguchi Method. International Journal of Mechanical Engineering and Technology, 8(4), 2017, pp. 223 232 http://www.iaeme.com/ijmet/index.asp 311 editor@iaeme.com