Fabrication of a Model Go-Kart (With Low Cost) – Mechanical Project

Abstract:

There are many motor sports in the world. Bikes, Cars, Formula one are examples of them. The drivers in these are very professionals and accurate. They can drive it very fast. But there are also motor sports which do not need professional drivers and need no great speed. The vehicles used are also very cheap. Such a motor sport is Go-Karting. They resemble to the formula one cars but it is not as faster as F1 and also cost is very less. The drivers in go-karting are also not professionals. Even children can also drive it. Go-karts have 4 wheels and a small engine. They are widely used in racing in US and also they are getting popular in India. Go-Karting is a big craze to the Americans and Europeans. It is initially created in United States in 1950s and used as a way to pass spare time. Gradually it became a big hobby and other countries followed it. In India go-karting is getting ready to make waves. A racing track is ready in Nagpur for go-karting and Chennai is also trying to make one. Indian companies are also producing go-karts in small scale. MRF and Indus motors are the major bodies in karts and they are offering karts between 2 lakh and 3 lakh. But to make go-karts popular, the price must come down. For that, many people are trying to build one under 1 lakh and we had also take up the challenge and make our under 78 K. This is a dream come true. A go-kart just under Rs. 100000/-. So we are sure that our project will have a high demand in the industry and also we are hoping to get orders from the racing guns.

Introduction:
Go-kart is a simple four-wheeled, small engine, single Seated racing car used mainly in United States. They were initially created in the 1950s, Post-war period by airmen as a way to pass spare time. Art Ingles is generally accepted to be the father of karting. He built the first kart in Southern California in 1956. From then, it is being popular all over America and also in Europe. A Go-kart, by definition, has no suspension and no differential. They are usually raced on scaled down tracks, but are sometimes driven as entertainment or as a hobby by non-professionals. Karting is commonly perceived as the stepping stone to the higher and more expensive ranks of motor sports. Kart racing is generally accepted as the most economic form of motor sport available. As a free-time activity, it can be performed by almost anybody and permitting licensed racing for anyone from the age of 8 onwards. Kart racing is usually used as a low-cost and relatively safe way to introduce drivers to motor racing. Many people associate it with young drivers, but adults are also very active in karting. Karting is considered as the first step in any serious racer’s career. It can prepare the driver for highs-speed wheel-to-wheel racing by helping develop guide reflexes, precision car control and decision-making skills. In addition, it brings an awareness of the various parameters that can be altered to try to improve the competitiveness of the kart that also exist in other forms of motor racing.

Go-Karts In India
Home of go-karts in India. Many people take part in the racing and is getting popular. Go-karts emerged in India in 2003 from MRF, which has a 250cc two-stroke engine, which produce 15 bhp of power, which costs around 3 lakh. Indus motors are also offering Go-karts for 2 lakh to 3 lakh. There are racing tracks in Nagpur for go-karting, which is known as the home of go-karts in India. Many people take part in the racing and is getting popular.

Parts Of A Go – Kart :

In a Go-Kart, there are mainly six parts.

They are

1. Chassis,

2 .Engine,

3. Steering,

4. Transmission

5. Tiers

6. Brake, and

7. Electric Starter.

Working Of Automatic Transmission :
This go-kart has no gears and clutches. The transmission we use is not manual, it is automatic. For this purpose, we use continuously variable transmission. We use pulley and belt system type CVT.

For example, when the pitch radius is small on the driving pulley and large on the driven pulley, then the rotational speed of the driven pulley decreases resulting in a lower ‘gear’. When the pitch radius is large on the driving pulley and small on the driven pulley, then the rotational speed of the driven pulley increases resulting in a higher ‘gear’. Thus in theory, a CVT has an infinite number of ‘gears’ that it can run through at any time, at any engine or vehicle speed

Fabrication

Chassis: The chassis is constructed with the GI pipe as per dimensions and bends in required places using bending machine. Then the pipes are welded rigid. Strength evaluation is made. The results obtained are The Max strength is 23.33n/mm2,strain 9.2 E-S and maximum displacement is .1157mm.

Axle: The required shaft is taken as per the dimensions and turned on the lathe Sprocket: The sprocket is welded on the axle at required place.

Brake: The brake is also placed in the axle in the left side. The boredom is connected to it and is connected to left pedal in front of kart. Accelerator: The accelerator pedal is placed is the right side of the front of the kart and is connected to the engine.

Engine: The engine is mounted in the chassis and the chain is connected to the sprocket and engine.

Fuel Tank: The fuel tank is placed in the upper position of the engine level using clamps and bolts.

Muffler: The two pipes are taken as per the dimension and join together. Then 3 ‘V‘ Shaped cuts are made in large cylinder and 3 washers are placed inside it and the ‘V‘ cuts are re welded and grinded. The inlet end of muffler is bolted to the exhaust of engine and also a rubber bush is placed to support the muffler.

Rear Wheels And Tyres: The 2 wheels are connected to the both ends of the axle and bolted together. Then the assembly is connected to the chassis using 2 bushed bearing.

Steering: The steering spindle and steering are made as per the dimensions and bolted together. This is connected to the plate and link mechanism. This mechanism is connected to the 2 front wheels. Seat: First the seat is mounted on seat stand using bolts and the seat is bolted on the chassis.

Electric Start: The battery is placed under the seat and connected to the starting motor using wires. And the switch is placed in the steering spindle stand.

Painting: The painting is done to increase the appearance to the kart. The chassis, steering and steering spindle, wheels, seat, muffler, engine cover etc. are painted using different colours. The pedals are also painted.

Estimation And Costing : Costing may be defined as systematic procedure for recording accurately every item of expenditure, incurred on the manufacture of a product by different departments of any manufacturing concern.

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