Design of Roll Cage Model For All Terrain Vehicles

Abstract

The paper focuses on software design methods and analysis of the roll cage for an All-Terrain Vehicle (ATV). The roll cage is crucial for the safety of the driver and the vehicle\\\'s occupants, and the study outlines a step-by-step design methodology using Solid Works and Creo. The design process includes material selection, shape, and welding, followed by Finite Element Analysis for safety and reliability. Static and dynamic stress analyses are performed, and the roll cage is designed to offer double strength in case of rolling while considering aesthetics.

Introduction

I. INTRODUCTION

The primary goal of this study is to design a roll cage that will provide maximum protection to the occupants of a vehicle in case of an accident. The roll cage is a specially engineered and constructed framework that is built in the passenger compartment of a vehicle to protect its occupants in case of a rollover or other accidents. The study begins by designing a model for the roll cage using Solid works and Creo software, taking into consideration the intended use and size of the vehicle. The design is modified based on requirements such as the type of roads the vehicle will be driven on.

To ensure the roll cage's efficacy, Finite Element Analysis (FEA) is conducted using Ansys/Lisa software to analyze the roll cage's strength in various scenarios such as front and rear collisions, rolling, front and rear bumps. Material selection, the shape of the roll cage, and welding material are also crucial design criteria. The load is calculated using energy theorems, and no assumptions are taken while calculating the force on the roll cage in different conditions.

Based on the results of the analysis, the design is modified accordingly to provide maximum protection to the vehicle occupants. Overall, this study emphasizes the importance of designing a roll cage that meets specific requirements and is structurally sound, as it is the foundation of a vehicle's safety system.

II. LITRETURE SURVEY

Several studies have been conducted on the design of roll cages for all-terrain vehicles (ATVs). These studies have explored various aspects of roll cage design, including material selection, shape optimization, and the use of simulation techniques.

One study focused on the use of composite materials in roll cage design for ATVs. The study found that composite materials can provide a high strength-to-weight ratio, making them an ideal choice for roll cage construction. Another study investigated the use of topology optimization to design roll cages for ATVs. The study found that topology optimization can be used to reduce the weight of the roll cage while maintaining its strength and stiffness.

In addition to these studies, simulation techniques such as finite element analysis (FEA) have been used to analyze the performance of roll cages under various loading conditions. One study used FEA to investigate the performance of roll cages in ATV rollover accidents. The study found that the shape of the roll cage can significantly affect its ability to protect occupants in rollover accidents.Overall, these studies highlight the importance of careful design and analysis in the development of effective roll cages for all-terrain vehicles.

III. METHODOLOGY

It sounds like you have described a methodology for designing a roll cage. The flow chart suggests that you started with gathering detailed information from a previous design and then used this information to create a new design.The previous design had a high number of welding nodes, which may not have been sufficient to ensure the driver's safety. Therefore, you selected a new design and material with maximum fatigue and tensile strength to avoid reducing the strength and changing the original properties of the pipes.

To verify the effectiveness of the new design, you conducted front, rear, and side impact test analyses using Ansys software, which is commonly used for simulation and analysis of engineering problems.

Overall, it appears that you have followed a structured and iterative approach to design a roll cage that ensures the driver's safety by selecting appropriate materials and verifying the effectiveness of the design through simulation analysis.

IV. DESIGN

A. Material

After thorough comparison of many opted materials, final selection of material for roll-cage of ATV was finalized based on the following criteria:

1. High Purpose of utility.
2. High Strength of Material
3. Light weight
4. Low cost
5. Feasible size
6. Availability of the material.

TABLE NO 1. PROPERTIES OF MATERIALS

From above table it is clear that the best suitable material for the Model of Roll-Cage is ASI 4130,

Best Material: AISI 4130

a. Less weight

b. Less deformation

c. Better factor of safety

d. Good Strength

e. But high cost 400 rupees/meter

TABLE NO 2. ALLOWABLE VS DESIGNED VALUE

B. Number of Nodes

At nodes pressure points are created which results in failure of the design model. The design to be optimum should consist of minimum number of nodes. The Nodes should be minimum to avoid the pressure points.

C. Welding Techniques and Material

There are different types of welding techniques available for the material being used, including Gas tungsten arc welding, Gas Metal arc welding, and Resistance/spot welding. Resistance/spot welding is cheaper and more effective for retaining the strength. The optimal welding material should be reasonably priced and suitable for the application, with Tungsten rod being the most suitable choice.

D. Design Software

SolidWorks 2019 was used for designing the roll cage, which offers a user-friendly interface and easy material customization. The design approach followed in this study was based on a case study that analyzed earlier designs in detail, identifying weak points and making changes accordingly.

We have remodeled the previous design for better performance.

The basic properties of all the designs are:

1. Diameter: 30 mm
2. Material: AISI 4130
3. Modulus of elasticity: 210 Gpa
4. Fatigue strength: 320 mpa
5. Outer diameter: 30 mm
6. Thickness: 2 & 3 mm
7. Inner diameter: 27 & 28 mm

Conclusion

For designing a roll cage involved a systematic approach that included gathering detailed information from a previous design and using it to create a new design. The previous design had a high number of welding nodes, which raised concerns about the driver\\\'s safety due to high stress at the welding joints that could reduce the strength and alter the properties of the pipes. To address these issues, a new design was created, taking into account the lessons learned from the previous design. The new design included a reduced number of welding nodes and the selection of a material with maximum fatigue and tensile strength which is steel AISI 4130 The design was modelled using design software, and the final stage of the process involved conducting front, rear, and side impact test analyses using Ansys software to verify the safety and effectiveness of the design. Overall, the design methodology involved a rigorous and iterative approach that focused on minimizing welding nodes, selecting appropriate materials, and ensuring safety through simulation and testing analysis.

References

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Copyright

Copyright © 2023 Yash Patil, Pranav Pahilwan, Rusihkesh Vaskar, Rutuj Upadhye, Prof. S. M. Jadhao. 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.