NKRC 2015

TEAM ID-NKRC15-023
TEAM-DRONA

1.1 ABSTRACT
To design an on-road vehicle which will provide
an ergonomic drive to the driver while keeping
in mind the primary objective of high strength to
weight ratio, cost efficiency, better traction and
acceleration. This document provides details
about every aspect of the design prototype including the decisions to use various components.
The vehicle has been designed using computer
aided modelling and simulation, resulting in a
safe, high-performance vehicle for on-road
competition with high strength and durability. The report diagnoses the attributes of each
of the vehicles, subassemblies; highlighting the
considerations , functions, and processes behind

is to build the vehicle for utmost ergonomics, to

achieve this the Kart is build for maximum space
and also the distance between the driver's arm
and steering, also distance between driver's knee
and pedal both are kept optimum so that minimum fatigue is induced in the driver.
As a whole, the main objective of the team is to
reduce the weight of the vehicle, augment the
performance and minimize the power loss. Each
part is being designed using Auto Cad and
Solid Works by keeping in mind these objectives. An iterative process is being used for the
same. Benchmarking will be done in selection of
each component. A special attention will be given
to the manufacturing processes to improve the
overall quality of the final product.

their design.
DIMENSIONS (inch)

PARAMETER

1.2 Introduction/Design
methodology:Sanghvi institute of management and science
earlier made three gokarts. In last event we
occupy overall 24th rank in India.
The goal of TEAM DRONA is to make the best
performing Kart that will embody all the
NKRC requirements.
To achieve our goal the team has been divide into
various groups and each group is assigned a specific component of the vehicle (Roll cage, ,
Wheel Assembly, Steering and Brakes, Power
transmission). For designing , analysis and optimization of the vehicle components various
software like Auto Cad (design) , Solid works
(Analysis), is available. Main focus of the team

Weight (with driver)

110kg

Wheel Base

1219.2mm

Wheel Track

965.2mm

Height of CG

228.66mm

Ground clearance

50.8mm
ENGINE

Type

Honda shine 125 cc

Max torque , Nm@rpm

10.54Nm@5700rpm

Max power , Kw@rpm

10.3kw@7200rpm
TRANSMISSION

Manual gear transmission

Direct chain drive on shaft

STEERING
linkage

4 bar link assembly

BRAKES

Rear brakes

Hydraulic disc brakes

TIRE SIZE (inch)

Front (ODWIDTH-ID)

117-5

Rear (DWIDTH-ID)

10*7-5

#2#

FRONT VIEW

STANDARD VIEW

1.3 Chassis/Frame MaterialThe selected material has 0.18% carbon as per

rule book (AISI 1018) which has yield tensile
strength of 370 MPa , so that it gives better load
bearing capacity. According to rule book, two
types of tubes are used having same material but
different cross sectional area. Primary members OD =25.4 mm, thickness = 3 mm Secondary
REAR VIEW

SIDE VIEW

members - OD=25.4 mm ,thickness=1 mm

MATERIAL PROPERTIES

VALUES

Ultimate tensile strength

440 MPa

Yield tensile strength

370 MPa

Modulus of elasticity

2.05105 MPa

Poisson ratio

0.29

Density

7870 kg/m3

Elongation and brake (in 50

mm)

15 %

#3#

Analysis Reviews

FRONT IMPACT
REAR IMPACT

SIDE IMPACT

1.4 Calculations :1.4.1 Transmission :

Objective :- To transmit maximum torque from
the engine to the drive wheels with help of Chain
Drive

#4#

d) Vehicle max Velocity:

Vmax = 2 NR 60/3.14 1000 0.7

e) Vmax= 56.91 km/hr
f) TIRE SIZE :
As per the rule book the maximum speed of the
vehicle is limited to 60 kmph so by using the formula :R = (1000 V G)/(2 60 N)
where ; R = radius of the tyre
V = maximum speed
G = overall Gear Ratio
N = engine RPM
R = (1000*60*2.2)/(2*60*7500)
R = 0.14666m
R = 5.77
D = 11.54
The nearest standard tire size available in the
market has a daimeter of 11

Calculations:
a) Static load on the kart,
Load on front
Wfs = WcL

Engine Rpm
6000
5000

= 1079.1 19.6/49

4000

= 431.64 N

3000

Load on rear

Engine Rpm
2000
1000

Wrs = WbL

= 1079.1 29.4/49

20

40

60

= 647.66 N
b) Maximum Traction from Ground:
Fmax = . w/L.(c-frc.h)/1-h/L
Fmax = 504.51 N
c) Vehicle maximum Acceleration:
ax

= ( fmax - fW ) (m?)

Here ?= 1.08
ax

= 4.1m/s2

Power (KW)
12
10
8
6
power (KW)
4
2
0
0

20

40

60

1.4.2 Steering Design :-

1.4.3 Brake Design

#5#

The steering system was to be chosen with the

Speed Vs Stopping Distance

low in cost and weight and has good efficiency

and sensitivity. Ergonomics is also taken into account.
Calculations:
Here,
B = Front track width
= 965.2mm,
W = Wheelbase
= 1219.2mm,
Maximum inner angle
= ?i= 40
Length of the steering arm = 203.2mm
General Equation:(1tan?i) (1tan?o) = (BW)
Oo= 27.13
Turning Radius:R1 = (Wtan?i) + (B2)
R1 = 1.69m
where , R = Minimum turning radius
R = v (R1 + b)
R = 2.0 m
Ackerman Angle:
tana = (B2) W
= 20.78
Length of Tie rod:Sina = y length of Ackerman arm
y = 2.839inch
Length of tie rod = track width 2y
Length
of tie rod = 32.322inch
PARAMETERS
VALUES
Toe in Angle

Ackermann Angle

20.78

Outer Angle

27.13

Inner Angle

40

Steering arm

Turning radius

1.69m

Min. Turning radius

2.0m

Tie rod length

32.322

20
15
10
5
0
10

20

30 40 50
Speed(km/h)

60

Velocity Vs Stopping Time

Stopping Time(sec)

complexity. We took linkage mechanism as it is

Stopping Distance(m)

main focus being handling, durability and less

2
1.5
1
0.5
0
10

20 30 40 50
Velocity(m/sec)

60

R = (D/2)+1

#6#

Now ,
Tr= 67.729 Nm
Torque found in the wheel
Tw=Torque found in the tire(Tt)
Tw=Tt = Tr
=67.729 Nm
Force reacted between the tire and the ground (assuming friction exists to support the force) ,

Force output of the brake pedal assembly ,

Fbp = Brake pedalforce pedal ratio
Fbp = 100 (6/2)
= 300 N
Hydraulic pressure generated by the master
cylinder ,
Pmc = Fbp/ Ta
= 775193.7984 N/m
Pressure transmitted to the calliper ,
Pcal = Pmc
= 775193.7984 N/m Valu
Mechanical force generated by the calliper ,
Fcal = Pcal Area cal.
= 1284.496 N
Clamp force generated by the calliper
Fclamp= 2 Fcal
= 2568.992 N
Frictional force generated by brake pads
Ffriction=Fclamp X bp(coefficient of friction)
=950.527 N
Torque generated by the disc ,
Tr =Friction x R (Effective Radius)
Here, effective radius is to be calculated by

Ftire =Tt / Radius of the tire

=484.812 N
Total braking force reacted between the vehicle
and the ground (assuming adequate traction exists) ,
Ftotal = 2 484.812
= 969.634 N
DECELERATION :
Deceleration of the vehicle ,
a =Ftotal / mv(mass of the vehicle)
a =8.81 m/s
STOPPING DISTANCE:
Assuming the initial speed of the vehicle to be
60km/hr.
S=v/2a
=15.75 m
STOPPING TIME :
t =v/a
t = 1.89 sec

#7#

1.5 Safety

1.7 Financial Aspects from the

Projects

1.) Driver Suit - Fire resistant , SFI rated or FIA.

The overall estimated cost of the proposed this

vehicle is sponsored by the college .
The workshop and transportation facilities is
also provided by the college.

2.) Underclothing - It should be of Cotton wear.

3.) Helmet - Snell , SFI or FIA
4.) Balaclava
5.) Neck Support
6.) Gloves

1.8 College Fascillities

7.) Shoes - SFI , FIA or DMP

8.) Socks
9.) Kill Switch
10.) Rear View mirror
11.) Brake over travel switch

1.6 Electrical Components

1.Brake light
2.Indicator
3.Horn
4.Battery
5.Kill switch
6.Keys

1.9 References
1.) GKDC Rule book 2015
2.) Kirpal Singh Automobile Vol-1
3.) Wikipedia

2.0 Software Used

1.) Creo Parametric 2.0
2.) Solid works 2013
3.) ANSYS

THANK YOU