International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 12 | Dec 2025
p-ISSN: 2395-0072
www.irjet.net
Finite Element and Analytical Investigation of a Go- Kart Braking System Aditya Bhardwaj1, Farhad Danish2, Naeem Choudhary3, Habib ur Rehman4, Rahul Gupta5, Ajit Kumar Singh6 1,2,3,5,6 Department of Mechanical and Automation Engineering, G B Pant Government Engineering College, New
Delhi, India
4Department of Mechanical Engineering, IISC Bengaluru, Karnataka, India
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Abstract - Go-karts are open wheeled racing kart, which
designed and analytically tested in order to achieve sufficient performance, structural integrity, and thermal safety.
require efficient, and effective braking systems to guarantee the safety of the driver and the controllability of the vehicle. Due to their light weight, moderate operating speed, and lack of any kind of suspension mechanisms, the rear braking designs are widely embraced to reduce the complexity of a system, low cost and weight. This study is an analytical and finite element study of a rear-mounted hydraulic disc braking system that would be used in a go-kart and on a dry track. Braking system is also analysed with stopping distance, braking time, pedal force, hydraulic pressure, braking force, transfer of weight dynamically, and also with thermal loading. The choice of the material to be used in making the brake disc and pedal is done depending on the mechanical and thermal performance requirements. The Finite Element Analysis (FEA) is used to confirm the analytical predictions by structural and thermal modelling of the brake disc and structural analysis of the brake pedal. The analysis indicates that there is a high level of agreement between the analytical and numerical results and the highest level of deviation is under 5% in the maximum temperature. The braking system shows sufficient factor of safety in structural integrity and thermal overload and is thus suitable in a safe and effective operation of the gokarts. The research gives an approved design methodology, which can be applied as a reference to the development of gokart braking systems in the future for student events.
Every go-kart braking is determined by the mass, velocity, coefficient of friction of tires and the surface of road, and weight transfer in braking. On dry surfaces, there is sufficient friction to enable braking to be carried out adequately by using a single rear disc without adversely affecting stability [2]. Because go-karts have low center of gravity and short wheelbase, in case of over-braking on the front, the wheels might lock or become unstable. Rear-only braking as such thus offers a fair trade-off between safety and control especially in the entry level and amateur racing use. The paper is dedicated to the analytical research and finite element confirmation of the rear-mounted hydraulic disc braking system of a go-kart that works in dry conditions on the road. The analysis method commences with the calculation of braking force which is based on the principles of vehicle dynamics. The basic requirements include vehicle mass, initial velocity, desired deceleration, tire, and road coefficient of friction to determine the required rear axle braking torque. These are computed to determine the minimum performance of the braking system [3]. Hydraulic analysis is important in providing assurance that the force exerted on the pedal is transformed to be enough clamping force in the brake calliper. The hydraulic braking system comprises of a master cylinder, brake lines and calliper assembly. The analytical assessment of the relationship between pedal force, master cylinder pressure, and calliper piston force using the Pascal law is done. Adequate sizing of the master cylinder and calliper pistons helps to achieve the right balance of braking power and pedal force without too much effort on the pedal which is essential to the comfort and safety of drivers [4].
Key Words: Go-kart braking system, hydraulic disc brake, finite element analysis, thermal analysis, braking dynamics.
1. INTRODUCTION Go-karts are low-weight racing cars, but they are mainly used in recreational and competitive motorsport purposes, and simplicity, low price, and performance are the important design factors. In comparison to traditional cars, go-karts usually have a moderate speed, and do not possess complicated systems of suspensions. Therefore, the braking needs of go-karts are varied as compared to full size vehicles. It is common to find most of commercial and competition gokarts use rear-only braking systems since they offer the necessary level of stopping force with the lowest level of system complexity, total weighting, and cost of production [1]. Nevertheless, even being seemingly straightforward, rear-mounted braking systems have to be thoroughly
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The other critical feature of braking system design is thermal analysis because the kinetic energy is transferred to heat during braking. Over a rear mounted disc brake, the heat is dissipated by the brake disc and air around it. Analytical thermal model is used to approximate the increase in temperature during repeated instances of braking. Higher temperatures may result in wear and tear of the brake, material wear or breakages. Thus, the thermal capacity of
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