Static Finite Element Analysis of Roll Cage of Patrolling ATV Developed by CSMT, BSF Academy Tekanpur

Abstract

An All-Terrain Vehicle (ATV) roll cage is a structural arrangement that gives three-dimensional protection for the driver in the event of a rollover or abrupt impact accident, while also supporting the subsystems. In order to ensure that an ATV is structurally well-balanced and can protect the driver from impacts from the terrain, it should meet regulations with a proven design, few structural elements, light weight, great strength, and should be tested for unexpected impact loading. The objective of present work is to formulate a conceptual design followed by analysis of roll cage of robust 3-seater ATV need to be fabricated by CSMT, Tekanpur for the BSF frontiers at creeks of Gujarat. Ansys student 2024 R1 is used for analysis under defined constraints like front, side and rear impact on the roll cage. Three types of materials AISI 4130, AISI 1020 (DOM), and AISI 1018 are used for comparative analysis of crash test. This work provides the well-studied and optimal design approach on ATV roll cage to improve its impact bearing capability with better weight reduction and enriched strength ratio for a long duration. The research aims to give an introduction to the material selection procedure that need to be done before finalizing the design, using FEA software. In present work, various factors such as impact force calculations, loading points, generated Von-Misses Stress, deformation and Factor of Safety (FOS) are studied. The result of Finite Element Analysis (FEA) simulation showed least stress and deformation with highest factor of safety to suggests AISI 4130 as best suitable material for fabrication of roll cage.

Introduction

I.  INTRODUCTION

The American National Standard Institute defined all-terrain vehicles as vehicles with three or four low-pressure tyres with a driver straddling the seat and guiding the vehicle. As the name implies, the variety of terrains can be handled by the ATV and it can be driven on the gravel roads better than most other vehicles[1].An All-Terrain vehicle (ATV) roll-cage often known as the vehicle chassis is a skeletal structure that protects the driver as well as the powertrain, suspension, and steering systems. The roll cage, serve as the primary structural support for the vehicle other subsystems. The chassis main function is to handle various static and dynamic conditions without creating member deflections[2].The performance of ATV roll cage was studied against crashes that can be encounter in the real-life scenario and its consequences on the individual components, which must be designed to ensure the safety of the driver while not compromising the ergonomics[3].

Finite element analysis (FEA) was used in an attempt to optimise the rollcage, and the effects of stress and deformation were investigated for a linear static frontal impact study on the roll cage structure. The impact of additional auxiliary structures, such as the engine mount, gearbox, and other vehicle components, attached to the frame was investigated further. When the Von-Mises stresses were less than the material's yield strength and the structural components' deflections were sufficiently favorable to ensure the driver's safety, the structure's design was considered safe[4].

Particle swarm optimization algorithm along with the artificial immune algorithm is combined to address the multi-objective optimization problem of improving rollover crashworthiness while reducing mass, and the Pareto solution set exhibits superior uniformity and diversity[5].To ensure that the occupants remain secure in the event of an impact, a finite element model of the car is produced and computationally tested. In order to innovate the design of the Body in White (BIW) component of the car. A body-in-white (BIW) portion of the vehicle is taken, and the roll cage which is constructed with the material properties of carbon fibre (ePA-CF) and ASTM A36 steel (comparison) is taken for the dynamic analysis using ANSYS Workbench and LS DYNA [6].

The roll-cage's design is an essential component that determines the ATV's success; if it malfunctions, the driver and passengers will be in grave danger. As a result, the roll-cage of an all-terrain vehicle is designed with the driver's safety, ease of manufacture, durability, compactness, light weight, and ergonomics in mind. The roll cage is composed of thin, seamless pipes that are welded together to form a sturdy framework that can endure hard circumstances at the site of operation and vehicle flips that end upside down [7]. The roll cage is designed to meet the specifications of designed ATV mentioned in Table-1

Conclusion

Considering safety in every respect, for the driver, crew & drive components of the 03-seater ATV the results drawn from FE analysis are mentioned below: 1) The solution phase of FEA showed lowest values of deformation for AISI 4130 material under all three cases of impact loading. From nominal values of deformation which is 0.5mm for front impact it can be concluded that the roll cage can effectively protect the driver from any injury during the event of a frontal crash of the vehicle. 2) The post processing phase of FEA showed least equivalent Von-mises stress for AISI 4130. The developed stress is 25% and 46% lower than AISI 1020 and AISI 1018 material under front impact loading. 3) A considerable Factor of Safety (FOS) or design factor which is above 1.5 is obtained for AISI 4130 this will minimize the risk of failure and possible resulting injury[11]. FOS value implies the safe value of applied loads and deformations. The analysis confirms the vehicle\\\'s roll-cage durability in harsh environments and assist in material selection. Although it is challenging to continue with the designing and analysis of only roll cage, because there are numerous tests required to be performed under practical conditions.To maximize the material\\\'s effectiveness and strength, both the primary and secondary components of the roll cage will be made from the same material, i.e., 4130 AISI. The chassis design showed it’s ability to support a wide range of loads and manoeuvre over the marshy terrain found at Gujarat\\\'s Frontiers and Creeks. ACKNOWLEDGMENT The authors wish to acknowledge students of automobile engineering department of RJIT, BSF academy Tekanpur for providing assistance in present analysis.

References

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Copyright

Copyright © 2024 Manish Chandra, Anil Kumar Verma , Gaurav Saxena. 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.