Development and Modification in IC Engine for Supra Kart (Review Paper)

Abstract

The design of the transmission system for a student formula styled racecar using a KTM RC 390 bike engine is one of the best choice for the engineering students who design the motorsport vehicles for all the student race car competitions. As there are many rules and restrictions on engine usage such as capacity, type of fuel usage permitted, maximum power allowed of engine and many more. In addition, this report emphasize on the suitable type of drivetrain system, type of transmission and diffrential drivetrain. The present report shows the analysis and various parametric data’s of stock KTM RC 390 Engine and the drivetrain of the car.

Introduction

I. INTRODUCTION

The FSAE (Formula Society of Automobile Engineering) is a interdisciplinary student made, formula car designing competition held at national and international level. In this competition, students from various organizations /institutions design & build a formula car. The driver of the car should be one of the members of the team and therefore it becomes essential that the vehicle needs to be manageable and safe for the driver. The FSAE puts rules and limitation on the car. Event management also provides the rule book.

The system transmits the power developed by the engine of automobiles to the wheels of the motor vehicle to move the motor vehicle forward or backward. Power train is also called drive train/transmission. It consists of a group of components in a vehicle that delivers power to the driving wheels. Components present in the motor vehicle are engine, clutch, gear box, drive shaft, differential, axles, and cooling system. The vehicle’s reliability was improved as a result of the power train simulation in this study. After knowing the requirements of the power train system, looking at both advantages and disadvantages of different parts, with the careful selection of the engine platform, KTM 390 was selected. Fuel efficiency is also a key role in racing events for that design of air intake with the restrictor diameter of 20 mm. The purpose of designing the power train without compromising the driver safety precautions is achieved and the power train of formula student race cars has been designed by following the SAE International rules.

II. DESIGN CONSIDERATIONS OF ENGINE

The heart of a vehicle is the engine, which converts chemical energy (fuel energy) into mechanical energy. According to the competition regulations, the engine used to power the automobile must be a four-stroke cylinder with a displacement of no more than 710 cc per cycle. If more than one engine is utilized, each engine’s displacement must be less than 710 cc, and all engine’s intake air must flow via a single air intake restrictor. Two-wheeler motorcycle engines such as the KTM390, CBR600, and Royal Enfield 350 are available for engine choice.

In the proposed paper for the design of power train, various parameters were taken into consideration. As per the rules of SAE and formula imperial engine was selected on the basis of high-power output under 710 cc segment considering less about the torque. Speed transmissions have been selected for the gear, train, and RPM and torque was evaluated for different gears and accordingly. There are multiple mechanisms available like belt, pulley drive, direct mesh gear system, and chain drive. Various drags such as aerodynamic drag as well as friction resistance were taken into consideration and their empirical relations according to the aerodynamics of the vehicle were evaluated. Apart from torque and power, the fuel efficiency factor was considered and the air intake runner was designed accordingly.

III. WORKING

A. Steering

The  steering system chosen is Ackermann steering, designed to align the vehicle's trajectory to driver requirements or  race track conditions. The challenge of ensuring the wheels track circles with different radii  inside and outside corners prompted Ackermann's development of  steering geometry. This geometry contains the interconnected components of the steering system of a car or other vehicle. Ackermann steering geometry, a common configuration for all cars, solves the problem of achieving the correct steering angle when cornering or turning corners.

B.  Suspension

All suspension components in a road car are  present in a Formula 1 car. These parts include control arms, anti-roll bars, shock absorbers, springs, and shock absorbers. The suspension must support high loads. The suspension of a Formula 1 car must be strong and rigid to withstand the stresses of cornering at high speeds without damage. The main function of suspension is to attach the vehicle to its wheels. It doesn't have to be, because moving  heavy loads requires a complex system made up of many parts.

C. Braking System

Disc Brakes: One of the biggest advantages of a Formula 1 car is its braking system. Formula 1 cars use carbon fiber reinforced composite brake discs. When the disc heats up due to the friction between the disc and the brake pad, the coefficient of friction between the pad and the disc can reach 0.6. These higher temperatures result in higher wear rates on steel brake rotors.

Conclusion

As a result of this study\'s powertrain simulation, vehicle reliability was improved. Most engineering students dream of developing powertrains with lower power-to-weight ratios. Engine selection plays an important role in the powertrain. A square motor was selected as it produces more power compared to torque. In a racing car, power is more important than torque. Once you know the requirements of your drivetrain system, look at the pros and cons of the various components. Thanks to the careful selection of the engine platform, the KTM 390 is recognized as the best engine in its segment. This is because the power required exceeds the torque. In a racing car, power is more important than torque. Fuel efficiency is important along with power, and the power delivery environment is also important. Choosing chain drive reduces power losses. It seems reasonable to continue research into ways to improve the reliability of cars and minimize their weight. We achieved our goal of designing a powertrain without compromising driver safety measures, and the drivetrain was designed for Student Formula racing cars in accordance with SAE international regulations.

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Copyright

Copyright © 2024 S.R. Ikhar, Devanshu Madke, Atharva Pohankar, Atharva Nandanwar, Pranay Phophre, Samyak Meshram. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.