MATERIALS FOR GO-KART KNUCKLE OPTIMIZATION AND …

OPTIMIZATION AND COMPARATIVE ANALYSIS OF ALLOY MATERIALS FOR GO-KART KNUCKLE

Dr. Barmavatu PraveenDepartment of

Mechanical Engineering, Anurag University (Anurag Group of

Institutions), Venkatapur, Hyderabad, India-500088.*praveen205.bps@gmail.

com; [email protected]

u.inK. Rachana

Department of Mechanical Engineering,

Anurag University (Anurag Group of

Institutions), Venkatapur, Hyderabad, India-500088.

Voruganti SharanyaDepartment of

Mechanical Engineering, Anurag University (Anurag Group of

Institutions), Venkatapur, Hyderabad, India-500088.

Abstract:

Racing is an extensively complicated activity of sports at higher level. In India Go Karting has started attracting the hearts of young engineers and new entrant drivers and this is because of the popularity of F1 racing. Knuckle joint plays a vital role in the go-kart vehicle; it is a kind of hinged joint between two rods. This joint is used for connecting two rods whose axes either coincide or intersect and lies in a plane, joint movement allowing in only one plane. In Go-kart vehicles, these joints are mostly used in between front wheel and tie rods of steering system. Any Failure of knuckle joints leads to accidents and uneven movement of front wheel, which causes a huge loss. Thus, it is necessary to design and analyse the knuckle joint for withstanding heavy loads in the working condition. In this project, two different alloy materials (EN19 steel alloy & Aluminum alloy) are used for the analysis and the best-suited material will be opted for the manufacturing. The design has developed in 3D model by using SOLIDWORKS 16.0 software to get the precise measurements. The 3D model is then analysed by using ANSYS 19.2 software on two different alloy materials where several forces are applied on the structure, these results are obtained in the form of deformations. A prototype is made after the analysis with best suitable material and its working will be examined.

Keywords: Go-Karting; knuckle joint; Design; Analysis; Alloy Materials.

Introduction:

Aut Aut Research Journal

Volume XI, Issue VII, July/2020

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Knuckle joint is a universal mechanical joint used in structures construction to connect two intersecting cylindrical rods, whose axes lie on the same plane. This joint allows some angular movement between the cylindrical rods (in their plane). It is particularly designed for withstanding tensile loads. In Go-Kart vehicle, these joints are used in steering system in between front wheel and tie rods. The main parts of knuckle joint mainly related in this research are: 1. RODS – Which are to be connected by joint 2. SINGLE EYE – Modified rod for assembly 3. DOUBLE EYE or FORKED EYE – Modified rod for assembly 4.PIN – Connects two rods 5. COLLAR – To keep the pin in position 6. SPLIT PIN or TAPER PIN – To prevent sliding away of pin. The modelling and analysis of knuckle joint is done by using SOLID WORKS and ANSYS software’s respectively.

Fig.01 Shows the Exploded view of Knuckle Joint.

Literature:

Barmavatu Praveen & S.Chakradhar Goud (2019) [1] stated that composite alloys are the combined mixture of two or more constituents which have more potency and strength. Their complete research has carried out on composite alloy materials for fabricating the compact heat exchanger of automobile vehicles for heavy heat transfer applications. They used SS304+Flyash alloy material for increasing the thermal resistivity and SS316+cu alloy material for enhancing the thermal conductivity. The exact demanded goal of the research is to opt the most suitable materials for the design and optimizing the manufacturing processes in an eco-friendly way.

Aditya Pawar et al (2019) [2] done in-depth research on the Design & Analysis of steering system for a Professional Go Kart vehicle. In India the demand in popularity for F1, the go karting has come in the limelight, which made their attention to develop this project. They explained that the steering system would play the major role in reducing the lap time with slighter changes in the design of this system. Any failure in the steering system would give heavy impact leads to serious injury or loss to the team. Development of steering system has been made with slighter changes in the Design and analysis (knuckle, kingpin, Tie rod, pitman arm or tripod, steering column and steering wheel).

Objectives:



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To recognize the complications in the present and future anticipations which are associated in the movement of steering system knuckle joint.

To recognize the best alloy material for the development of knuckle joint which can withstand maximum loads and increases the performance of the go-kart vehicle steering system.

To rise the significances of knuckle joint by investigating the future scope development with its potentiality.

To design the knuckle joint of the go-kart steering system with unadorned way of use.

Material Data:

EN19 steel alloy:

EN19 steel also named as AMERICAN SAE 4140 material. EN19 Engineering Steel is a high tensile steel, which have good ductility and shock resistance properties. It is a best high quality alloy engineering steel material with high quality medium carbon.

Aluminum alloy:

Aluminum alloy allows the use of various reinforcement and material improvements. This alloy has greater strength and stiffness. The best property in this material are controlled weight and reduced density.

Table 01. shows the properties of the materials.

Material EN19 steel alloy Aluminum alloy

Maximum deformation

0.019125 mm 0.019128 mm

Maximum stress 1.0343e+10 pa 1.0235e+10 pa

Factor of safety 1.78 1.5

Table 02. indicates the steps to Design Knuckle Joint.

Steps Failure Equation To find

Step 1 : Design of Rods (D,D1)

TensileEmpirical

D= 12 mmD1= 13.2 mm

Step 2 : Decide the thickness of eye end and forked end (t1,t2)

Empirical relations t1= 1.25 Dt2= 0.75 D

1 = 15 mmt2 = 9 mm

Step 3 : Decide the Double shear d1=1.5 d d = 10 mm



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dimensions of pin (d,d1)

Bending failureEmpirical d= 9.2 mm

{Choose higher value of both}

Step 4 : Check Stresses in Eye end

EmpiricalTensileShear

Crushing

d0=2d d0= 20 mmcheckcheckcheck

Step 5 : Check Stresses fork end

TensileShear

Crushing

checkcheckcheck

Modelling:

Modelling of various parts of go-kart steering system knuckle joint has been carried out by using SOLIDWORKS 16.0 software.



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Above Fig.02 shows modelling of (a) C-clamp, (b) Nut, (c) Bolt, (d) Stub axle (e) knuckle joint by using SOLIDWORKS 16.0 software.

Result of Structural Analysis:



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Finite element analysis (FEA) is an essential and indispensable technology used for modelling and simulation of latest engineering problems such as manufacturing transportation, housing and building design. Knuckle joint having diameter 12 mm is taken into account for the Analysis considerations. After converting assembled SOLID WORKS model into IGS format, it is then imported into ANSYS 19.2 software.

Fig.03 shows the meshing of Knuckle joint

Fig.04 shows the knuckle joint with 110KN stress applied.

EN19 steel alloy:



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Fig.05 shows the Equivalent stress of knuckle joint C-clamp (EN19 steel alloy).

Fig.06 shows the Total deformation of knuckle joint C-clamp (EN19 steel alloy).

Fig.07 shows the Equivalent stress of knuckle joint stub axle (EN19 steel alloy).



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Fig.08 shows the Total deformation of knuckle joint stub axle (EN19 steel alloy).

Aluminum alloy:

Fig.09 shows the Equivalent stress of knuckle joint C-clamp (Aluminum alloy).

Fig.10 shows the Total deformation of knuckle joint C-clamp (Aluminum alloy).



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Fig.11 shows the Equivalent stress of knuckle joint stub axle (Aluminum alloy).

Fig.12 shows the Total deformation of knuckle joint stub axle (Aluminum alloy)

Fabrication:



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Above Fig.13 (a), (b), (c) shows the Fabrication and assembly of knuckle joint in the Go-Kart vehicle steering system.

Conclusions:

Table 03. shows the comparative result analysis of EN19 steel alloy and Aluminum alloy at 110KN load.

Material EN19 Steel Alloy Aluminum Alloy

Maximum Deformation 0.019125 mm 0.019128 mm Maximum Stress 1.0343e+10 Pa 1.0235e+10 Pa Factor of safety 1.78 1.5

In this project the complications in the present and future anticipations has found which have associated in the movement of go-kart vehicle steering system. Optimization of various alloy materials (EN19 steel alloy and Aluminum alloy) has made and the best alloy material for the development of knuckle joint has recognized to withstand maximum loads by using FEA technique.



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It has been found that knuckle joint made of EN19 Steel alloy have less stress developed for a load of 110KN as compared to Aluminum alloy and have highest factor of safety i.e. 1.78 compared to aluminum. Therefore, we can prefer the EN19 Steel alloy for the development of knuckle joint in Go-Kart vehicle steering system.

References:

1. Barmavatu Praveen & S.Chakradhar Goud (2019), “Fabrication of Compact Heat Exchanger with Composite Alloys”, International Journal of Innovative Technology and Exploring Engineering, 8(6S4), 717-721pp.

2. Aditya Pawar et al (2019),“Design and Analysis of a Professional Go Kart Steering System”, International Journal for Scientific Research & Development, 7(4), 996-1002pp.

3. Tejas pawar et al (2019),“ Numerical evaluation of Knuckle Joint with stainless steel material for total deformation and Von Mises analysis”, IOP Conf. Series: Materials Science and Engineering, 810 (2020) 012062 IOP Publishing doi:10.1088/1757-899X/810/1/012062, ICEMEM-2019.

4. Abhishek Joshi et al (2019), “Review Paper on Steering System of Go- KART”, International journal of innovative research in technology, 5(12), 509-510pp.

5. Mihir M. Pewekar et al (2018), “Design of subsystems of Go-kart vehicle”, International Journal of Science, Engineering and Technology Research, 7(1), 18-31pp.

6. Sajid Khan et al (2018), “Design and Stress Analysis of Knuckle Joint of Different Material Using CAE Tools”, International Journal of Engineering Technology Science and Research, 5(5), 278-285pp.

7. Avinash Barve et al (2018), "Detailed design calculations & analysis of go-kart vehicle", International Journal of Emerging Technologies and Innovative Research, 5(8), 259-273pp.

8. Nipun kumar, Gian bhushan, Pankaj chandna (2017), “The analysis of knuckle joint of various materials using CAE tools,” International journal of engineering technology, management and applied sciences, 5(1), 45-52pp.

9. R. S. Rajendran, S. Sudalaimuthu,M. Sixth (2013), “Knuckle Development Process with the help of Optimization Techniques,” Altair Technology Conference, India.

10. W. M. W. Muhamad, E. Sujatmika, H. Hamid & F. Tarlochan (2012), “Design Improvement of Steering Knuckle Component using Shape Optimization,” International Journal of Advanced Computer Science, vol. 2(2), 65- 69pp.

11. R. Roy, S. Hinduja and R. Teti (2008), “Recent Advances in Engineering Design Optimization: Challenges and Future Trends,” CIRP Annals – Manufacturing Technology, 697– 715pp.

12. K. S. Chang, P. S. Tang (2001), “Integration of Design and Manufacturing of Structural Shape Optimization,” Advances in engineering software, 32(1), 555-567pp.

13. Gupta, R.S. Khurmi, J.K. (2008). A textbook of machine design (S.I. units): [a textbook for the students of B.E. / B.Tech. U.P.S.C. (Engg. Services); Section 'B' of A.M.I.E. (1)](14th ed.



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MATERIALS FOR GO-KART KNUCKLE OPTIMIZATION AND …