Mn = 0.4-0.

6%
Chassis C = .280-.330%
Si = 0.15-0.30%
Mo = 0.15-0.25%
Introduction S = 0.04%
P = 0.035%
The primary function of a roll cage is to protect the
Welding
driver, give a rigid support for the assembly of sub systems, The material which is used AISI 4130 has
engine and drive train. The roll cage is designed to meet the good weld ability. All welds on the vehicle are made
technical requirements of competition. The objective of the using a MIG welding process. MIG welding uses an arc
chassis is to encapsulate all components of the kart, including a of electricity to create a short circuit between a
driver, efficiently and safely. Proper numbers of members are continuously fed anode (+ the wire fed gun) and a
used in the roll cage to ensure complete driver safety. These cathode (- the metal being weld). MIG is selected
include the front and rear bumpers, the side bumper, battery because it provided the best control of heat affected
cover and firewall as per the specifications in the rule book. The zones while also reducing internal stress in the frame
bumpers are so designed that they will serve as protection from selected in order to allow the weld to flex slightly without
front and rear and will also add impressive look to the kart. All cracking. It provides strongest welds, faster welding
the bends are of constant radius. In this design, uniform speed and is clean and efficient, and makes welding
thickness pipes are used because of ease in welding. easier.

Design parameters 2. Finite element analysis

Structural integrity of the frame is verified by
comparing the analysis result with the standard values
Wheelbase 42
Front Track Width 40
1. of the material. Analysis was conducted by use of finite
Rear Track Width 42 element analysis (FEA) on ANSYS software. To conduct
Height of RRH 45 FEA of the chassis, an existing design of the chassis
Outer Diameter 25.4mm
Thickness 2.5mm was uploaded from the computer stresses were
No. of Welds 34 calculated by simulating three different induced load
Pipe Length 18m
cases. The load cases simulated were frontal impact,
MATERIAL
The selection of material for chassis is done by detailed side impact, and rear impact. The test results showed
study of properties of material regarding strength and costs, that the deflection was within the permitted limit.
results found that two materials AISI 1018 and Chromoly (AISI Meshing -
Auto meshing has been done in ANSYS 14.5
4130) can be used for the frame. But AISI 4130 is preferred over
software. Following data has been found after
AISI 1018, because of its higher yield strength and high strength
meshing of chassis-
to weight ratio.The material AISI 4130 is used in the chassis No. of nodes = 353049
design because of its good weld ability, relatively soft and Front Impact-
For the front impact, engine and driver load was given
strengthens as well as good manufacturability. A good strength
at respective points. The kingpin mounting points and rear
material is important in a roll cage because the roll cage needs
wheels position are kept fixed. Front impact was calculated for
to absorb as much energy as possible to prevent the roll cage
an optimum speed of 60kmph. From impulse momentum
material from fracturing at the time of high impact. AISI 4130 has
equation, 4g force has been calculated. The loads were applied
chosen for the chassis because it has structural properties that
only at front end of the chassis because application of forces at
provide a high strength to weight ratio.
one end, while constraining the other, results in a more
conservative approach of analysis. Time of impact considered is
Properties of material
0.2 seconds as per the industrial standards.

Ultimate Strength 560MPa

Yield Strength 460MPa
TThe chemical composition of material is- Density 7850 kg/ m 3
Fe = 97-98%
Elongation 21.5%
Cr = 0.8-1.1%
 V iV f applied by constraining left side of chassis and applying
)
F t=m load equivalent to 2.5g force on the right side.
F 0.2=180 ( 16.380 ) V iV f
)
F=14.7 KN F t=m
F 0.2=180 ( 8.190 )
Deformation 1.47mm F=7.35 KN
Maximum Stress 209.4MPa
Factor of Safety 2.04

Deformation 1.46mm
Maximum Stress 277.5MPa
Factor of Safety 1.17

Rear Impact-
Considering the worst case collision for rear impact, force is
calculated as similar in front impact for speed of 60kmph. The
value of 5g force has been calculated. Load was applied at rear
end of the chassis while constraining front end and kingpin
mounting points. Time of impact considered is 0.2 seconds as
per industrial standards.
V iV f
)
F t=m
F 0.2=180 ( 16.380 )
F=14.7 KN

Side impact-
The most probable condition of an impact from

Deformation 2.74mm
Maximum Stress 302.71MPa
Factor of Safety 1.73
the side would be with the vehicle already in motion. So
it was assumed that neither the vehicle would be a fixed
object. For the side impact, the velocity of vehicle is
taken 30kmph and time of impact considered is 0.2
seconds as per industrial standards. Impact force was