Abstract: A roll cage is a skeleton of a vehicle.

The roll cage forms a structural

base and a 3D shell around the driver. The objective of the study is to analyze and
optimize the roll cage designed under a set of particular rules given by ISIE
(Imperial Society of Innovative Engineers).Here both the designing and analysis is
done on Solid works and Ansys. Static structural for different collisions like front,
side, rear and roll over of the roll cage is done in solid works. The main objective
of analysis is to obtain optimum factor of safety which ensures that the roll cage
of the vehicle will be safe in all conditions.

Introduction: The design factor contains safety, easy manufacturing,

durability & maintenance of the frame and a compact, lightweight & ergonomic
design. Besides this its purpose is to provide the seating comfort to the drivers,
providing safety and incorporating other sub-systems of the vehicle, the main
purpose is to form a frame or so called Chassis.

MATERIAL COMPOSITION AND PROPERTIES

CHEMICAL COMPOSITION
The chemical composition of AISI 4130 alloy steel is listed in the following table.
Element Content (%)
Iron, Fe 97.03 – 98.22
Chromium, Cr 0.80 – 1.10
Manganese, Mn 0.40 – 0.60
Carbon, C 0.280 – 0.330
Silicon, Si 0.15 – 0.30
Molybdenum, Mo 0.15 – 0.25
Sulfur, S 0.040
Phosphorous, P 0.035
PHYSICAL PROPERTIES:
The following table shows the physical properties of AISI 4130 alloy steel.

Properties Metric Imperial

Density 7.85 g/cm3 0.284 lb/in³
Melting point 1432°C 2610°F

MECHANICAL PROPERTIES:

The mechanical properties of AISI 4130 alloy steel are outlined in the following table.

Properties Metric Imperial

Tensile strength, ultimate 560 MPa 81200 psi
Tensile strength, yield 460 MPa 66700 psi
190-210 27557-
Modulus of elasticity
GPa 30458 ksi
Bulk modulus (Typical for steel) 140 GPa 20300 ksi
Shear modulus (Typical for steel) 80 GPa 11600 ksi
Poisson’s ratio 0.27-0.30 0.27-0.30
Elongation at break (in 50 mm) 21.50% 21.50%
Reduction of area 59.6 59.60%
Hardness, Brinell 217 217
Hardness, Knoop (Converted from Brinell hardness) 240 240
Hardness, Rockwell B (Converted from Brinell hardness) 95 95
Hardness, Rockwell C (Converted from Brinell hardness, value
17 17
below normal HRC range, for comparison purposes only.)
Hardness, Vickers (Converted from Brinell hardness) 228 228
Machinability (Annealed and cold drawn. Based on 100%
70 70
machinability for AISI 1212 steel.)

Mass properties of frame

Pipe diameter

Pipe Outer diameter = 26.9mm Inner diameter = 19.10mm

Mass = 46033.85 grams

Volume = 5864185.31 cubic millimeters

Surface area = 5759428.88 square millimeters

Center of mass: (millimeters)

X = 818.98
Y = 1.76
Z = 353.08

Principal axes of inertia and principal moments of inertia: ( grams * square

millimeters )
Taken at the center of mass
IX = (1.00, 0.00, 0.01)
IY = (0.00, 1.00, -0.02)
IZ= (-0.01, 0.02, 1.00)
PX = 4743959428.82
PY = 21315650495.38
PZ= 22019512376.67

Moments of inertia: (grams * square millimeters)

Taken at the center of mass and aligned with the output coordinate system.
LXX = 4746720059.78 LXY= 2946734.21 LXZ = 218346165.00
LXY = 2946734.21 LYY= 21315918996.59 LYZ = -13720376.09
LZX = 218346165.00 LZY = -13720376.09 LZZ = 22016483244.50

Moments of inertia: (grams * square millimeters)

Taken at the output coordinate system
IXX= 10485696180.53 IXY = 69337060.61 IXZ = 13529806026.38
IYX= 69337060.61 IYY= 579312306.22 Iyz = 14901805.43
Izx = 13529806026.38 Izy = 14901805.43 Izz = 52893104
ANALYSIS AND SIMULATION OF FRONT IMPACT:
1. BEAM DETAILS:
Beam-22(Structural Section Standard- Beam- Section Standard-
Member1[30]) iso/pipe/isie 56(Trim/Extend7[1]) iso/pipe/isie
Section Area: Section Area:
172.159in^2 172.159in^2
Length:295.752mm Length:448.909mm
Volume:4.91145e- Volume:7.53336e-
005m^3 005m^3
Mass Mass
Density:7850kg/m^3 Density:7850kg/m^3
Mass:0.385549kg Mass:0.591368kg
Weight:3.77838N Weight:5.79541N

Beam-24(Structural Section Standard- Beam- Section Standard-

Member1[21]) iso/pipe/isie 4(Trim/Extend3[1]) iso/pipe/isie
Section Area: Section Area:
172.159in^2 172.159in^2
Length:350.431mm Length:296.376mm
Volume:6.02545e- Volume:4.98263e-
005m^3 005m^3
Mass Mass
Density:7850kg/m^3 Density:7850kg/m^3
Mass:0.472998kg Mass:0.391137kg
Weight:4.63538N Weight:3.83314N

Beam-7(Trim/Extend3[2]) Section Standard-

iso/pipe/isie
Section Area: 172.159in^2
Length:350.568mm
Volume:6.02416e-005m^3
Mass Density:7850kg/m^3
Mass:0.472896kg
Weight:4.63438N

2. LOADS:

Load calculation formula:

Force = (Mass* acceleration)/time

Mass calculation:
a. Weight of the vehicle: 230kg(2256.3N)
b. weight of the driver: 71.5(701.42N)
c. Total weight = 301.5 kg(2957.715 N)
 Speed of the vehicle on impact = 45km/hr.

= 12.5 m/s

Time= 0.35 sec.

Force= (301.5 * 12.5)/0.35 = 10768 N

3. Mesh information:

Total Nodes 759

Total Elements 712

4. Results:
a. Bending stress

Maximum: 4.46938e+008 N/m2 Minimum: 0 N/m2

 b. Resultant Displacement:

Maximum: 2.20582 mm Minimum: 00 mm

c. Factor of safety:

Maximum Factor of Safety: 1.03

 d. Shear Force:
Maximum: 5.355e+3 N Minimum: -5.94e+3 N

ANALYSIS AND SIMULATION OF REAR IMPACT:

1. Beam details:

Section Standard- Beam-61(Structural Section Standard-iso/pipe/isie

Beam-57(Structural iso/pipe/isie Member1[4]) Section Area: 172.159in^2
Member1[62]) Section Area: 172.159in^2 Length:436.133mm
Length:248.26mm Volume:7.48405e-005m^3
Volume:4.10333e-005m^3 Mass Density:7850kg/m^3
Mass Mass:0.587498kg
Density:7850kg/m^3 Weight:5.75748
Mass:0.322112kg
Weight:3.15669N

Beam- Section Standard-

63(Structural iso/pipe/isie Beam-58(Structural Section Standard-iso/pipe/isie
Member1[65]) Section Area: 172.159in^2 Member1[14]) Section Area: 172.159in^2
Length:248.632mm Length:614.447mm
Volume:4.10374e-005m^3 Volume:0.000105439m^3
Mass Density:7850kg/m^3 Mass Density:7850kg/m^3
Mass:0.322143kg Mass:0.827697kg
Weight:3.157N Weight:8.11143N
 2. Load:
Load calculation formula:
Force = (Mass* acceleration)/time
Mass calculation:
a. Weight of the vehicle: 230kg(2256.3N)
b. Weight of the driver: 71.5(701.42N)
c. Total weight= 301.5 kg(2957.715 N)

Acceleration of the vehicle = 45km/hr.

= 12.5 m/s
Time: 0.45 sec

Force= (301.5 * 12.5)/0.4

= 9422 N

3. Mesh details:

Mesh type Beam Mesh

Total Elements 3479
Total Nodes 3616
4. Results:
a. Bending stress:

Maximum : 4.42738e+008 N/m2 Minimum: 0 N/m^2

 b. Displacement:

Maximum: 1.86182 mm Minimum: 00 mm

c. Factor Of Safety:

Maximum Factor Of Safety: 1.04

 d. Shear force:

Maximum: 2.961e+003 N Minimum: -1.276e+003 N

ANALYSIS AND SIMULATION OF SIDE IMPACT:

1. Beam details:
Beam-37(Structural Section Standard- Beam-45(Structural Section Standard-
Member1[37]) iso/pipe/isie Member1[36]) iso/pipe/isie
Section Area: 172.159in^2 Section Area: 172.159in^2
Length:701.793mm Length:247.54mm
Volume:0.000108578m^3 Volume:4.07331e-005m^3
Mass Mass
Density:7850kg/m^3 Density:7850kg/m^3
Mass:0.852337kg Mass:0.319754kg
Weight:8.3529N Weight:3.13359N

Beam-44(Structural Section Standard- Beam-46(Structural Section Standard-

Member1[24]) iso/pipe/isie
Section Area: 172.159in^2
Length:702.649mm
Volume:0.000115801m^3
Mass Density:7850kg/m^3
Mass:0.909036kg
Weight:8.90855N
Member1[16]) iso/pipe/isie
Section Area: 172.159in^2
Length:552.203mm
Volume:9.51148e-005m^3
Mass Density:7850kg/m^3
Mass:0.746651kg
Weight:7.31718N

Beam-49(Structural
 Member1[6]) Section Standard- Beam-66(Structural Section Standard-
iso/pipe/isie Member4) iso/pipe/isie
Section Area: 172.159in^2 Section Area: 172.159in^2
Length:557.826mm Length:622.658mm
Volume:9.60857e-005m^3 Volume:0.000107196m^3
Mass Density:7850kg/m^3 Mass Density:7850kg/m^3
Mass:0.754273kg Mass:0.841492kg
Weight:7.39187N Weight:8.24662N

2. Load:
Load calculation formula:
Force = (Mass* acceleration)/time
Mass calculation:
a. Weight of the vehicle: 230kg(2256.3N)
b. Weight of the driver: 71.5(701.42N)
c. Total weight = 301.5 kg(2957.715 N)

Acceleration of the vehicle = 45km/hr = 12.5 m/s

Time: 0.5 sec

Force= (301.5 * 12.5)/0.45 = 8375 N

3. Mesh details:

Total Nodes 3721

Total Elements 3584

4. Results:
a. Bending stress:

Maximum: 7.0963e+8 N/m2

Minimum: 00 N/m2
b. Displacement:

Maximum: 5.5299mm Minimum: 0 mm

c. Factor Of Safety:

Maximum factor of safety= 1.06

d. Shear force:

Maximum: 4.65e+003 N Minimum: -4.540e+003 N

TORSIONAL RIGIDITY:
Torsional rigidity is the ratio of torque applied about the centroid al axis of a
bar at one end of the bar to the resulting torsional angle when the other end is
held fixed. This test is necessary as it will be helpful while cornering of the
vehicle and will also help us to know about the handling of the vehicle. If the
torsional rigidity is small then vehicle will be comfortable but if the torsional
rigidity is large the vehicle will be uncomfortable, which will affect the driver
and the handling of the vehicle.

Two opposite wheels will be fixed and load will be applied on the other two
wheels.

1. BEAM DETAILS:
Beam-5(Structural Member1[42])
Section Standard-iso/pipe/isie
Section Area: 172.159in^2
Length:400.182mm
Volume:6.5916e-005m^3
Mass Density:7850kg/m^3
Mass:0.517441kg
Weight:5.07092N

Beam-53(Structural Member1[15])
Section Standard-iso/pipe/isie
Section Area: 172.159in^2
Length:305.877mm
Volume:5.16327e-005m^3
Mass Density:7850kg/m^3
Mass:0.405316kg
Weight:3.9721N

2. Load:
Weight of the vehicle = 301.5 kg (including driver)
Weight acting on each wheel = w/4
=301.5 /4
= 75.38N on each wheel
 3. Results:
a. Bending Stress:

Maximum: 3.407e+6 N/m2 Minimum: 0 N/m2

b. Displacement:

Maximum: 0.054258 mm Minimum: 0 mm

 c. SHEAR FORCE:

Maximum: 3.720e+1 N

Minimum: -4.163e+1 N

ANALYSIS OF FRONT AND REAR UPRIGHT

MATERIAL COMPOSITION AND PROPERTIES:

Chemical composition :
Element Content (%)
Aluminum, Al 90
Zinc, Zn 5.6
Magnesium, Mg 2.5
Copper, Cu 1.6
Chromium, Cr 0.23
PHYSICAL PROPERTIES:
Properties Metric Imperial
Density 2.8 g/cm3 0.101 lb/in3
Melting point 483°C 900°F

MATERIAL PROPERTIES:
Properties Metric Imperial
Tensile strength 220 MPa 31909 psi
Yield strength 95 MPa 13779 psi
Shear strength 150 MPa 21756 psi
Fatigue strength 160 MPa 23206 psi
Elastic modulus 70-80 GPa 10153-11603 ksi
Poisson's ratio 0.33 0.33
Elongation at break 17% 17%
Hardness 60 60

LOAD POINTS:

FRONT UPPER A-ARM LOAD

FRONT LOWER A-ARM LOAD

FRONT CORNERING LOAD

RESULTS:

a. Total defomation:

Maximum: 3.4053e-005 m Minimum: 0. M

b. Maximum Shear Elastic Strain:

Maximum: 8.2702e-004 m/m Minimum: 9.1225e-007 m/m

 c. Shear Stress:

Maximum: -1.0446e+007 Pa Minimum: 1.5734e+007 Pa

REAR UPRIGHT:
1. LOAD POINTS:

REAR UPPER A-ARM LOAD

 REAR LOWER A-ARM LOAD

2. RESULTS:
a. Total Deformation:

Maximum: 3.4855e-005 m Minimum: 0. M

Maximum: 1.6404e+007 Pa Minimum: -1.5924e+007 Pa