TEAM NITTE RACING

DESIGN VALIDATION PLAN

Objective
The objective of design validation plan is to ensure the all components used in our Go-kart are on
good quality and perform their respective function to the needed standards and meet required
specification. The most important function of DVP is to identify and rectify potential problems in
mountings and the design itself. The secondary purpose of the DVP is to ensure that we meet the
OEM requirements for various components purchased and that we do not use any substandard
parts on the Go-kart.

IN Scope
The following tests are in scope of this design validation plan:
1)
2)
3)
4)
5)
6)

Mechanical tests
Metrological inspection
Visual inspection
Computer simulation
Performance tests
Electrical circuit testing

Mechanical tests
Mechanical tests like strength under torsional, shear and bending are in scope of testing

Metrological inspection
All components that are going to be fitted on the Go-kart will undergo a metrological inspection
where they will be accepted only if they are within the tolerance limit set for the specific part.

Visual inspection
A thorough visual inspection of all parts will take place for finding cracks, bends, surface abrasion
and any other imperfections.

Computer simulation

Project report/DVP

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A part where manual testing is not possible computer simulation is used.

Performance tests
The performance of the engines and brakes can be tested.

Electrical circuit testing

All electrical circuits for proper connections and wiring can be tested.

OUT of Scope
Testing methods such as Ultrasound and eddy current testing are out of scope due to unavailability
of the required setup.

Validation strategy
The DVP is divided based on subsystem
1) Chassis frame
2) Engine and Transmission
3) Brake
4) Steering
5) Safety
6) Maintenance
The validation process will give higher priority to the validation of the chassis frame by simulation.
Then the priority will shift to the testing and the validation of the tube steel that is to be used as it
is the paramount if we intend to stick to the fabrication timeline. All parts that are bought will first
undergo a thorough visual inspection in the store before buying the component.

Validation location and personnel

The entire validation process will be carried out in NMAM institute of technology campus using
equipment available beforehand. The metrology and measurements lab will be used to conduct all
measurements. The material testing lab will be used for mechanical tests. All personnel involved in
the design validation process will be either faculty of students of NMAM institute of technology and
outside help or consultation is only as a final measure when the expertise or equipment is not
available in-house. The validation process will be led by (********), a member of Team Nitte
Karting.

Project report/DVP

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Validation time line

The validation process will has started from 5th November with the validation of the chassis frame
by simulation (on ANSYS) and will end only once the Go-kart is fully functional and declared that no
viable improvements can be made. The physical validation will begin once the first component is
acquired.

DVR
The Design Validation Report will be prepared on each and every component validation and every
iteration of testing if there are more than one required. The design validation report will be
prepared with a fixed format as given below. The final DVR for the chassis structure is given after
the sample DVR.

Project report/DVP

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Test conducted:
Equipment used:
(date)

(subsystem)

(part)

(revision no)

(name)

(signature)

(title)
Validation plan for the XYZ component

Test parameters:
Test results:
Diagnosis (if any):
Supervisors signature.

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DVP by subsystem
Chassis frame: the design validation for the frame is done in a two pronged system where
first the frame is analysed using computer simulation for different working stresses such a static
load and impact load. And then the material is tested using for its mechanical properties by
conducting material tests.
The tests conducted on the chassis are:
Computer simulations under following load

Static load
Impact loads(front and side)
Torsion loads

Tests carried out on the physical material to find strength under

Tension loads
Bending loads
Torsional loads

The equipment required for conducting the tests are:

ANSYS software
Universal Testing Machine
Torsional test setup

The computer simulations for the frame have been done at the CAD lab of NMAM Institute of
Technology. The design was redesigned and modified until the factor of safety was up to the mark.
The design was analysed using ANSYS15 and the above mentioned simulations were conducted
All the material strength tests are going to be conducted in the material testing laboratory in the
NMAM institute of technology campus.
The material tests are going to be conducted once the material is available to work with.

Project report/DVP

TEAM NITTE RACING

Project report/DVP