Go Kart Kart Design - Finite Element Analysis (FEA) Go Kart for Maximum Strength

Abstract: Go Kart A square tube frame has been subject to questionable pipe layout and section problems. Finite Element Analysis (FEA) was chosen to maximize the strength of the frame in question and minimize weight.

Frame under consideration: Gamblighini Phi-Alpha 10 without a roll cell.

Download recommendations:

- torsional load
- Shock load

Frame weight: 300 pounds

200 pounds per person

Initial sectional properties: 1 x 1 inch .109 (12 GA), dropping to 0.070 to see the effects.

Material properties: ASTM A-36: 36,000 psi output

Introduction to Finite Element Analysis (FEA)

Finite Element Analysis (FEA) is a program that places many small “elements” in the model under consideration, and then calculates the effects of the load on the element. The effects of stress are stress and strain. Voltage is the amount of load that a particular element and voltage can handle, the amount of element deviation will be produced.

FEA can be manually connected using Matrix Math, but even then, high-performance computers are needed to work with the math nightmare. FEA is a fantastic tool for crunching a complex into a simple one; instead of doing it all by hand, a computer can survive millions of calculations in minutes.

What we want to do in this frame is to maximize strength and minimize weight.

As an introduction, there are several ways to launch analysis in this frame:

-Connection model
-Shell Model
Model cable element

Solid modeling

On a solid model, high-performance CAD software is required, which will draw the model in three-dimensional and tubular “real-life” structures. The model will have many elements, up to millions, and in fact they will be very difficult to run even on a very powerful computer. Thus, the typical "mental gymnastics" should be performed to reduce the size of the model and allow it to be calculated without using so much computer power.

For those who follow the path of continuous modeling, it is ideal to reduce areas of increased voltage to pieces that can be controlled. If you guess that the frame will be processed initially and have no idea where the stresses will occur, then the best route is either to cut the frame in half, reduce the number of elements and reduce the number of passes that the computer should calculate.

For all those new to FEA, he uses high-level math (i.e. Calculus on stereoids) and actually looks like shooting an arrow at a target. The first calculation tries to involve you in the common area of ​​the bull, the second calculation recalibrates and becomes much closer. Subsequent passes are getting closer. Two passes are usually enough to get an answer.

Imagine a computer scrolling through 100,000 equations at a time. This is what FEA requires from the computer if using solid particles.

Shell modeling

The second method is shells. The shells take the tube and assume that it is as thin as paper (in its view), then it presses the thickness and the moment of inertia (I) on the cross section. The good thing about shells is that it uses less brain energy and can actually give you an answer that is as good as a solid model. Problems associated with shells together. The assumption of shell modeling software can be deceiving.

Example: a square tube welded to a square tube at the side. The point of intersection is said to be fully welded along the entire boundary of the pipe. We all know that the tube receives only partial penetration, and the weld itself may or may not be large enough at the intersection. With this in mind, solids can give better results. If higher results are required, resort to solids in higher stress environments.

Farm Modeling

The third method is the farm calculation method. This is the lowest HP solution for everyone and gives good results. The truss model can be removed together after about 10 minutes, and results are achieved using a low-power computer. And to make things even better, a typical program can cost less than $ 1,000.

The overall frame design was introduced into the FEA software as a framework and will be calculated using the truss method. So, next time we will show how to put a frame of kart on the FEA program, using farm modeling.