Design and Analysis of EV Go-Kart Wheel Hub for Weight Reduction

Wheel hubs are critical load bearing components in electric go kart systems, directly influencing vehicle safety, handling, and unsprung mass. With increasing emphasis on lightweight design in electric mobility, conventional metallic wheel hubs present limitations in terms of weight reduction potential. This study presents the design and finite element based structural evaluation of a front wheel hub for an electric go kart using carbon fiber reinforced polyamide as an alternative to aluminium alloy. The wheel hub geometry is developed using an industrial reference and modelled using threedimensional computer aided design. Structural performance is evaluated through finite element analysis by considering static loading, transient loading, and braking torque conditions representative of real operating scenarios. Aluminium alloy and carbon fiber reinforced polyamide are analysed using identical geometry, boundary conditions, and loading configurations to enable a consistent comparison. The results indicate that the composite wheel hub exhibits stress levels comparable to aluminium while demonstrating acceptable deformation behaviour under all loading cases. Under transient and braking conditions, the composite material shows improved stress distribution characteristics, attributed to its inherent material damping and flexibility. In addition, the significantly lower density of carbon fiber reinforced polyamide offers substantial weight reduction potential without compromising structural safety. The findings of this study demonstrate the feasibility of using carbon fiber reinforced polyamide as a lightweight alternative to aluminium for electric go kart wheel hub applications and provide a foundation for further experimental and fatigue-based investigations.