This paper presents an approach to a go-kart chassis design, vehicle dynamics calculation, Li-ion battery capacity analysis, and electric motor choice for optimized vehicle performance. The chassis analysis shown in this paper was performed by a CAD/FEA software package, SolidWorks. Three highlights can be found in this paper: 1) an original design was implemented; the basic analysis was composed of chassis optimization using beam elements and modeling such an optimized chassis “locally” with solid elements for sub-modeling purposes. 2) The most stressed tube joint was sub-modeled to calculate the risk of tube wall stability. 3) Vehicle dynamics were calculated for the case of braking in a curved path and the case of a collision with the front tire on road imperfection. The authors intend to install a data acquisition system in the future to analyze the stress of local chassis tubes. The results of the SolidWorks analysis indicate a safety design of the chassis concept. The result for the sub-model stability (buckling) analysis show that the chosen tube wall thickness to diameter gives safety factor values ranging from 1.6 to 5.0. Based on the stress distribution, some improvement in the middle part of the chassis can be made from a half-a-millimeter thicker wall tube, or a larger diameter of the tube, by a few millimeters, to lower the stress. The latter will be described in the following paper.
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