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I will sure like solution and will rate up the work.thanks
Based on the Weighted Objectives above AISI 1018 was found to be a suitable choice
because of its excellent machinability and low cost.
Working as a group of design consultants you have been approached by a company who manufacture Go Karts for the leisure industry. This project involves carrying out a design study to modify their best-selling 'KMB1500'Kart replacing the usual petrol engine with an electric motor, associated battery and electrical control components. A major concern of the customer is the suitability of the rear axle, they have therefore decided to commission your company to completely redesign the rear axle taking into account the requirements of the new motor and those dictated by the application. Should the project be a success, then your customer will be able to launch their new product as a lower speed kart intended for use at indoor circuits where reduced noise levels and emissions would be desirable. In order to keep weight and cost to minimum, it has been decided that the rear axle will not require a differential, the axle will be chain driven from the motor with sprockets, these are available in sizes starting with 18 teeth and these increment in 1 tooth intervals upto a size of 500 teeth. Your customer has also stressed the importance of maintaining their reputation for very safe and reliable products. This is a one off prototype project but if successful, it would be hoped to manufacture around 100 units per annum for the next 6 years. Figure 1 on the following page outlines the pertinent dimensions of the kart which you should use to support your design work. Please note that C.O.G (Center of gravity) is calculated without the motor or battery / control module mounted to the kart. All Dimensions contained in this brief are in mm. The mass of the Kart with no electrical components is: 63kg. The mass of the Electric Motor is 18kg. The mass of the combined battery and electric control module is 8kg. The center of gravity of the battery / control module can be assumed to act at the centroid of its space envelope which is 150 x 150 x 110mm. This may be mounted in any orientation on the kart.
1100 099 405 KART C.O.G DRIVER C.O.G 180 150 670 825 1325 Figure 1: Layout Arrangement of Kart
Figure 2 below defines the speed / power characteristic of the motor used in the new arrangement. Power is transferred from the motor to the rear axle via a sprocket and chain drive system. Power (kW) 8 6 1000 250 500 750 Motor Speed (Rev/min) Figure 2: Electric Motor Characteristic Curve The geometry of the electric Motor is shown in figure 3. 280 50 0170 0110 P.C.D 025 4x MIO Figure 3: Electric Motor Geometry
SCOPE OF SUPPLY. Working in a team of four you are required to prepare a design proposal for the arrangement of the rear axle assembly and new components required by the electricfication. Any bought in components used in the arrangement must be accurately specified by manufacturer's name, type and size and the selection of the components used is to be backed by calculation. All calculations must be in Sl units. Calculations in imperial units will not be marked. Your design report is to contain the following sections which are to be submitted sequentially throughout the duration of the module: 1) A design specification for the Rear Axle assembly and addition of components required for the electrification of the kart. (Please note that this is a design specification and therefore needs to provide details of what it is you are required to design. Your specification must therefore be written in the future tense. Your specification must include all limitations imposed upon the design by the conditions described or implied above, as well as any further details you deem relevant. It should not include irrelevant details and must not be written as a product specification, i.e. NOT as a document which provides details of an already existing product). (Group Activity 10%) 2) A written review, not exceeding 1500 words of three different materials you believe might be used to manufacture the rear axle shaft transmitting the drive torque to the wheels. The associated manufacturing method for each material must also be included. From the three materials and manufacturing methods you review you need to select the one you deem most suitable for the intended application. This should be done in the form of a discussion listing the advantages and disadvantages of each material and by developing and comparing performance indices based on the conditions and requirements your group set out in your design specification as well as those listed or implied in the brief. Your discussion must take account of the relevant service conditions, cost considerations and most importantly ethical and environmental considerations. You may make use of CES to help with the material selection process, but this IS NOT essential. If you do use CES, please be aware, the output from the software on its own is insufficient. The software output MUST be accompanied by and supp ed with a clear explanation of the method and the findings of the analysis. A weighted Objectives Method is NOT required for this part of the exercise. For this submission, you must also provide a concept sketch (not CAD) of the layout of axle, bearings, sprockets, motor, battery in the context of the kart assembly. (Individual Activity 30%) 3) Based on the criteria you set out in your design specification and the requirements listed or implied in the brief, select the most appropriate material and manufacturing method from which to manufacture the rear axle and layout for the transmission design from those proposed by your group members, in 2) above. Your selection must employ the Weighted Objectives Method and you must provide a brief discussion and rationale for each of the objectives you use. You must also explain the rationale for the scores awarded. (Group Activity 15%)
4) Using the materials selected by your group in 3) above determine the required diameter(s) for the rear axle shaft transmitting the drive torque to the wheels. You must take into account combined bending and torsion in your calculations, any assumptions made must be clearly stated and you must select an appropriate factor of safety that you use in these calculations providing a suitable rationale for your choice. Please note that when determining the axle diameter(), STANDARD sized bought in components such as bearings MUST be available to suit your design and so the diameters you calculate may need 'rounding to a standard dimension. It is your responsibility to demonstrate that standard sized bought-in components are available to support your design. Failure to take account of this may result in significant loss of marks. Please note that all calculations and material properties MUST be shown in SI units only. (Group Activity 20%) 5) Prepare an engineering layout drawing of the rear axle assembly, including the means by which it mounted the kart and the drive sprocket is conne ted. Your drawing must include a border, parts list (with relevant details of all parts both manufactured and bought in) and a data box which provides details of drawing title, scale and angle of projection. (Group Activity 15%) 6) Prepare a plan for the manufacturing methods that might be employed in the manufacture of the rear axle from the raw material. In this case 'raw material' refers to the material as supplied by the material stockholders. It does not mean manufacturing from the ore. Your manufacturing plan must cover all features included in the axle required to achieve the drive between the clutch and the winch. Please note! No description of the manufacturing processes is required; you are simply expected to suggest the methods and the sequence of operations by which the axle shaft might be finish machined to the required standard. All processes, including any finishing processes, involved in the production of the axle should be included and your reasons for selecting them given. (Group Activity 10%) As in the real world of engineering design it is important to provide exactly what the customer has asked for. You need only provide answers to the questions asked. Additional answers to questions not asked will not be marked and will therefore not be awarded any marks. If you are in any doubt as to what has been asked for then please make further enquiries to obtain clarification. Finally, please be aware that the customer has a right to amend any of the details provided within this brief, at any time during the course of the "contract". All changes will be notified to the teams as soon as possible and may be subject to an increase or a decrease in the costs associated with the completion of the "contract”.