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Design and Development for Roll Cage of All-Terrain Vehicle

Conference Paper · April 2015

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 International Journal For Technological Research In Engineering (IJTRE)
Volume 2, Issue 7, March-2015
ISSN: 2347-4718

Design and Development for Roll Cage of All-Terrain Vehicle

Deepak Raina*, Rahul Dev Gupta, Rakesh Kumar Phanden
Department of Mechanical Engineering, M. M. University, Mullana (Ambala), INDIA

Abstract - BAJA is a collegiate competition sponsored by the Society of Automotive Engineers, India (SAEINDIA®). Its
aim is to build an All-Terrain Vehicle (ATV) as per the constraints given by the organizers. The growing popularity of
the competition coupled with the need to design safe and dynamically balanced ATV has led to the origin of the idea of
this paper. The process of Finite Element Analysis (FEA) is expensive and time consuming as well as simulating the
problem statement is unnecessarily tedious at an initial design stage. Therefore, it is always advantageous to do extensive
research on the basic requirements of roll cage design. To understand the changes that need to be incorporated in the
design, perform the static stress analysis first. This will offer a simplistic simulation criterion of the problem statement
and requires a lower computational time; and then dynamic analysis to validate the safety of the preliminary design. The
paper aims to give an introduction to the material selection procedure, pipe size selection and various tests that need to be
done before finalizing the design, using ANSYS® WORKBENCH 14.0. In this present work, various factors such as
impact force determination, loading points, the mesh size dependence of generated stress, Von-Misses Stress, Deformation
and Factor of Safety (FOS) are studied.

Keywords - Roll Cage, Analysis, All-terrain vehicle, Factor of Safety, Von-Misses Stress, Finite-Element Analysis

1. INTRODUCTION
The Society of Automotive Engineers (SAE) organizes design competitions to indulge students in the general
practices of mobility Engineering. One such student design activity is the SAEINDIA® BAJA event held each year
in Pithampur (India). The objective for the team of students is to develop a dynamically balanced vehicle to
withstand all kind of terrain during its mobility. The SAE BAJA vehicle development manual restricts the vehicle
weight, shape and size, and dimensions. The objective of SAE BAJA competition is to simulate real world
engineering design projects and their related challenges. Moreover, it develops the best performing vehicle with the
rugged and economical vehicle frame that satisfies all the SAE BAJA design requirements [Rulebook BAJA
SAEINDIA® 2014]. During actual road performance, any vehicle is subjected to loads that cause stresses, vibrations
and noise in the different components of its structure. This requires appropriate strength, stiffness and fatigue
properties of the components to be able to stand these loads. On top of that, quality of a vehicle, as a system, which
includes efficient energy consumption, safety, riding dampness and provision of comfort to the driver is highly
desired. Roll Cage is the structural basis of an All-terrain vehicle. The components of a vehicle like a Power Source,
Transmission system, Axles, Wheels and Tyres, Suspension System, Controlling systems like Braking , Steering etc.
, and also electrical system parts are mounted on the chassis frame. It is the main mounting for all the components
including the body. So it is also called as a carrying unit [Nagarjuna et al.,2013] Extensive Research has been
conducted in order to design each main component of the vehicle. It is considered that each component is
significant, and thereby designed the vehicle as a whole trying to optimize each component while constantly
considering how other components would be affected. This forced to think outside the box, research more
thoroughly, and redesign components along the way in order to have a successful design. The necessary parameters
were used to create a Qualitative Function Diagram (QFD) to determine which parameters were the most critical.
These key parameters ranging from most critical to least critical are safety, reliability, low cost, ease of operation
and maintenance, and overall performance. Considering the functional objectives and the rules laid by the SAE Baja,
a preliminary design of the Roll Cage structure was developed in a 3D environment using SOLIDWORKS® 2013.
As weight is critical in a vehicle powered by a small engine, a balance must be found between the strength and
weight of the design. To best optimize this balance the use of solid modeling and finite element analysis (FEA)
software is extremely useful in addition to conventional analysis. The Centre of Gravity was tried to keep in middle
of the vehicle & closest to the ground for optimum stability. The length of the vehicle was kept small so as to reduce
weight and maintain a desired center of gravity. Later the design is tested against all modes of failure by conducting
various simulations and stress analysis with the aid of ANSYS® 14.0 Software. Finite Element Analysis (FEA) is
carried out on 3D model of roll cage in cases of front impact, rear impact, side impact, Roll-over, Torsional Rigidity,
front bump & Rear bump, Modal analysis and Drop Test in ANSYS®. Based on the result obtained from the testing
the design is modified accordingly. The analysis showcases the distribution of Von Misses stresses and the

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Volume 2, Issue 7, March-2015
ISSN: 2347-4718

deformation of the frame members, when subjected to the applied loads. If the stress generated in the chassis
members was found to be above the yield limit of the material, the existing frame was modified for a safe design.
The new design was again subjected to the same analysis, and the iterations continued till the stress and deformation
was within the desired limit. After successfully designing the roll cage, it is ready to be fabricated.

This paper has been divided in various sections viz; Section 2 provides Design and Development for Roll Cage of
ATV, Section 3 presents the details of FEA, Section 4 gives the descriptions of Results and finally conclusions from
present work are drawn in section 5.

2. DESIGN AND DEVELOPMENT

The design and development process of the roll cage involves various factors; namely material selection, pipe size
selection, frames design and finite element analysis. The details of each step are given below.

2.1 Material Selection

One of the key design decisions that greatly increase the safety, reliability and performance in any automobile
design is material selection. As per the rule book constraint there should be at least 0.18% of carbon content in metal
[Rulebook BAJA SAEINDIA® 2014]. Our initial step was to conduct a market survey to have an idea of the
availability of the material. Based on market survey we have chosen following material namely: - AISI 1018 steel,
1020 DOM, and AISI 4130 steel. Table below gives a side by side comparison of these materials [Nayak et al.,
2012].
Table 1: Comparison of Material Properties
Property Material 1018 Steel 1020 DOM 4130 Steel
Density (kg/m3) 7870 7865 7850
Physical Properties Yield Strength (MPa) 370 480 460
Tensile Strength (MPa) 440 550 731
Carbon, C 0.14-0.20 0.05-0.26 0.28-0.33
Iron, Fe 98.81-99.26 99.08-99.53 97.3-98.2
Manganese, Mn 0.60-0.90 0.3-0.6 0.4-0.6
Chemical Properties
Sulphur, S ≤0.50 ≤0.05 ≤0.04
Phosphorus, P ≤0.40 ≤0.04 ≤0.035
Chromium, Cr - - 0.80-0.95

To ensure that the optimal material is chosen, extensive research was carried out. The key Categories for comparison
were strength, weight, and cost. The 4130 is selected due to its optimum strength-to-weight ratio. Further, the
properties such as high corrosion resistance and the availability of the metal enabled the choice of AISI 4130 steel in
the making of the roll cage [Kumar et al.,2013 ]. The roll cage is virtually designed as a tubular space frame.

2.2 Pipe Size Selection

As per guidelines, the primary members must be Circular steel tubing with an outside diameter of 25.4 mm (1 inch)
and a wall thickness of 3 mm (0.120 in) [Rulebook BAJA SAEINDIA® 2014]. Also, we were having a constraint in
selection of size for secondary members of the frame that the minimum wall thickness should be 0.89 mm (0.035 in)
and min outside diameter should be 25.4 mm (25.4 in). The bending strength and ease of fabrication is also taken
into consideration while deciding the cross section of pipe [Sharma et al. 2012]. To keep the weight of roll cage as
low as possible, we used the circular tubes with following dimensions:

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ISSN: 2347-4718

Primary Members: 25.4 x 3 mm

Secondary Members: 25.4 x 0.89 mm

Figure 1: Isometric View of frame

2.3 Roll Cage 3D Views:

Side View Front View

Top View
Figure 2: Orthogonal Views of Frame

3. FINITE ELEMENT ANALYSIS

3.1 Element Type:

The meshing has always been the key of the finite element model and for the exact solution of any object; it should
be properly meshed with relevant element shape and size. Generally for the solid bodies the tetra mesh is preferred,
so as we did [Matthias Goelke, 2014].

3.2 Assumptions:
a) The chassis material is considered to be isotropic and homogenous.
b) Chassis tube joints are considered to be perfect joints.
c) The „Crumple zone‟ phenomenon is not considered.

3.3 Mesh Size:

®
Meshing of roll-cage was carried out in ANSYS WORKBENCH 14.0. In finite element analysis, the degrees of
freedom is reduced from infinite to finite with the help of discretization or meshing (nodes and elements). Each
small volume is called an element. Each element has a set of points called nodal points or nodes [Matthias Goelke,
2014]. Nodes are usually located at the endpoints of elements.

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 International Journal For Technological Research In Engineering (IJTRE)
Volume 2, Issue 7, March-2015
ISSN: 2347-4718

The analysis was carried out using progressively reducing elemental sizes. The elemental size having consecutive
stress error less than 5% is generally considered as the optimum size of mesh. It means that any further decrease in
size will only negligibly increase the accuracy of the results. The stress values for different mesh sizes are as
tabulated in Table 2.
Table 2: Comparison of Mesh Sizes
Parameter Case I Case II Case III Case IV
Size of Mesh (Units) 40 20 10 8
No. of nodes 106684 219584 434629 485534
No. of Elements 74562 133446 236481 253079
Max value of Von-Misses Stress (MPa) 98.230 205.62 265.89 270.6
%age Error - 52.27 29.31 1.8
3.4 Calculations:

i) Impact Force Determination by Speed Limit:

According to the constraints in the rulebook, the maximum speed of the car is assumed to be 60km/hr. or roughly
around 16.66 m/s.
For a perfectly inelastic collision, the impact force is as calculated from Eqn. (1).
𝑚 ×𝑣 2 𝑚 ×𝑣 2
Wnet = ( 2 )final − ( 2 )initial … (1)
Where, Wnet is net work done on account of an inelastic collision.
𝑚 ×𝑣 2
Wnet = − ( 2 )initial … (2)
But Wnet = Impact force x d … (3)
Where d is the distance travelled during impact.
It is considered that for static analysis, the vehicle comes to rest in 0.1 seconds after impact. Therefore, for a vehicle
which moves at 16.66 m/s (or 60 km/hr), the travel of the vehicle after impact is 1.66 m. From Eqn. (1), (2) and (3),
we get:
𝑊
Impact force = 𝑛𝑒𝑡𝑑
𝑚×𝑣 2 1
Impact Force = ( ) initial × 𝑑
2
310 ×16.66 2 1
Impact Force = ( ) initial × 1.66
2
Impact Force (F1) = 25916 N
Therefore, Impact Force by Speed Limit (F1) ≈ 26,000 N

ii) Impact Force Determination by Acceleration Limit:

The „Motor Insurance Repair Centre‟ has analyzed that the Baja car will see a maximum of 7.9 G‟s of force during
impact.
F=mxa … (5)
Where, m = 310 kg, a = 7.9 x 9.8 m/s2
And Force = 24000.2 N
Therefore, Impact Force by Acceleration Limit (F2) ≈ 24000 N
These two values of F1 (from Eqn.4) and F2 (from Eq. No.5) are practically comparable.

iii) Impact Force Determination for Worst case Scenario:

According to research, a human body will pass out at forces much higher than 7.9 G‟s [Oturkar et al., 2013].
Therefore, a value of 10 G‟s was considered for an extreme worst case collision. Therefore for static frontal impact
analysis, the load on the vehicle is calculated from Eqn. (6).
F=mxa … (6)
Where, m = 310 kg, a = 10 x 9.8 m/s2
And Force = 30380 N
F3 ≈ 30000 N

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ISSN: 2347-4718

Thus a force of 30000 N or 10G is applied in the frontal impact analysis. The impact forces, as defined by
automobiles industry, for other tests are given in result table.

3.5 Loading Points and Constraints:

The forces are applied on the impacted part of the Roll Cage as it is the first point of contact in case of a collision eg.
In case of front Collision, forces are applied at front part and during side impact, forces are applied at Side Impact
Members (SIM) of Roll Cage. For Roll-over analysis, forces are applied at an angle of 45° to the impacted member.
The Suspension mounting Points on roll cage are fixed for all the static tests. For Front Bump, Forces are applied at
the Front Suspension Points and rear suspension points are fixed to analyze the situation; and vice-versa for rear
bump. A lot of failures brought about by resonance and excessive vibration of components and systems [Rajput et
al., 2013]. Therefore, Modal Analysis is done, in which the frame is fixed at the lower base of the vehicle frame to
know the different mode shapes of the upper substructure.

3.6 Von-Misses Stress:

Failure of mechanical components subjected to bi-axial or tri-axial stresses occurs when the strain energy of
distortion per unit volume at any point in the component, becomes equal to the strain energy of distortion per unit
volume in a standard tension test specimen during yielding. According to this theory, the yield strength in shear is
0.577 times the yield strength in tension [Dr. Sadhu Singh, “Strength of Materials”, Khanna Publishers India].
Experiments have shown that the distortion energy theory or Von-Misses Theory is better in agreement for
predicting the failure of ductile components than any other theory of failure.

4. RESULTS
The following results are obtained during different tests of Roll cage

Table 3: Result of Impact Test for Front, Rear and Side

Parameters Values Stress Analysis Deformation

Load Applied 10G

Max. Stress 270.65 MPa

Front

Max. Deformation 1.11 mm

FOS 1.69

Load Applied 5G

Max. Stress 313.29 MPa

Rear
Max. Deformation 1.96 mm

FOS 1.46

Load Applied 2G

Max. Stress 453 MPa

Side
Max. Deformation 2.39 mm

FOS 1.01

Table 4: Result of Bump Test for Front and Rear

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 International Journal For Technological Research In Engineering (IJTRE)
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ISSN: 2347-4718

Parameters Values Stress Analysis Deformation

1G
Load Applied

260.55MPa
Front Max. Stress

Max. Deformation 8.42 mm

FOS 1.76

Load Applied 1G

Max. Stress 356.12MPa

Rear
Max. Deformation 4.05 mm

FOS 1.29

Table 5: Result of Rollover Test for Front, Rear and Side

Parameters Values Stress Analysis Deformation

Load Applied 1G

Front Max. Stress 276.34MPa

Max. Deformation 2.00 mm

FOS 1.66

Load Applied 1G

Max. Stress 184.19Mpa

Rear
Max. Deformation 1.58 mm

FOS 2.49

Load Applied 1G

Max. Stress 184.19Mpa

Side
Max. Deformation 1.58 mm

FOS 1.09

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Table 6: Result of Torsional Rigidity

Parameters Values Stress Analysis Deformation

Load Applied 1G

Max. Stress 296.89MPa

Max. Deformation 3.77 mm

FOS 1.54

Table 7: Result of Drop Test

Parameters Values Stress Analysis Deformation

Drop Height 4 meters

Max. Stress 407.1MPa

Max. Deformation 3.19 mm

FOS 1.13

Table 8: Result of Modal Analysis

Mode No. Frequency (Hz)

7 42.577

8 45.203

9 53.236

5. CONCLUSION

Safety is of utmost concern in every respect; for the driver, crew & environment. A considerable Factor of Safety
(FOS) or design factor is applied to the roll cage design to minimize the risk of failure and possible resulting injury.
FOS value implies the safe value of applied loads and deformations. This clearly reaffirms the vehicle‟s ability to
withstand extreme conditions. The usage of finite element analysis was invaluable to the design and analysis of the
frame for All Terrain Vehicle. The designing and analysis is a difficult part to carry on as so many tests are needed
to be conducted with lot of constraints. The chassis was designed so as the vehicle can withstand all kinds of loads
and is capable of moving on terrains like hilly areas, Rocky Mountains etc. This paper thoroughly dealt with various
load analysis on Roll Cage. The chosen design was the safest & the most reliable for any long terrain.

REFERENCES

[1] Rulebook BAJA SAE INDIA 2015.

[2] D.Nagarjuna, Junaid Mohammed Farooq, A.S.N.Saiteja, P.Siddhartha Sri Teja. (2013). Optimization of Chassis
of an All-Terrain Vehicle. International Journal of Innovative Technology and Exploring Engineering (IJITEE),
2(2), 2278-3075

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Volume 2, Issue 7, March-2015
ISSN: 2347-4718

[3] Nayak, A. O., Ramkumar, G., Manoj, T., Kannan, M. A., Manik, D., & Chakravarthy, S. (2012). Holistic design
and software aided finite element analysis (FEA) of an All-Terrain Vehicle. Journal of Mechanical Engineering
Research, 4(6), 199-212.
[4] Parveen Kumar and Harsh Raghuvanshi. (2013) Innovative Design of an All-Terrain Vehicle (ATV).
International Journal of Engineering and Advanced Technology (IJEAT), 3(2), 2249-8958
[5] Vikas Sharma and Divyanshu Purohit. (2012). SIMULATION OF AN OFF-ROAD VEHICLE ROLL CAGE A
STATIC ANALYSIS. International Journal of Engineering Research and Applications (IJERA), 2(4), 126-128
[6] Matthias Goelke, (2014). “Practical Aspects of Finite Element Simulation”, Altair University INDIA
[7] Sanika Oturkar, Karan Gujarathi. (2013). An Introduction to Computational Frontal Static Stress Analysis of a
Baja Car. International Journal of Scientific and Research Publication, 3(8), 2250-3153
[8] Rajput, Y. S., Sharma, V., Sharma, S., & Saxena, G. (2013). A Vibration Analysis Of Vehicle Frame.
International Journal of Enginnering Research and Applications, 3(2), 348-350
[9] Sadhu Singh, (2012) “Strength of Materials”, Khanna Publishers, New Delhi, INDIA
[10] Chandrupatla, (2011) “Finite Element Analysis for Engineering and Technology”, University Press (INDIA)
Private Limited, New Delhi.

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