CHASSIS: -

DESIGN CONSIDERATIONS:

Purpose of Chassis is to serve various functions

like: Linking the Powertrain, Suspension,
Comfortable to operate, Driver ergonomics and
Safety issues and other design factors included
durability and maintainability of the frame.

1- Minimizing the weight of vehicle.

2- A compact vehicle.
3- Minimum cost of manufacturing.
4- Ease of maintenance and replacement of parts.
5- Acceptable level of safety.
6- To have an energetic look of an off-road vehicle.

Our team has taken a good consideration of 5

second escape and other clearances & tolerances
that are mentioned in rulebook.
The space frame is firstly drawn on paper to
accommodate the ease and behavior of design
aesthetics and only then modeled and analyzed in
SOLIDWORKS 2013
The Cross-sectional property of the space frame
roll bars are 25.4 mm O.D. and 3 mm wall
thickness.
MATERIAL USED

DESIGN METHODOLOGY:
The main objective of the frame is to provide a 3dimensional protected space around the driver
that will keep the driver safe. The space frame is
firstly drawn on paper to accommodate the ease
and behavior of design aesthetics and only then
modeled and analyzed in SOLIDWORKS 2013.
Prototyping was also done using PVC Pipes to check
the driver ergonomics & accommodation of various
subsystems as shown in fig and further changes
were made in design by several iterations.

Material Data - Steel AISI 1018

COMPOSITION:
Element
C
Mn
P
S
Si

Availability
Modulus of elasticity
Elongation
Elongation At Break
Result

Weight %
Thickness 3mm
0.18
0.74
0.02
0.03
0.16
AISI
1018
(M.S.)
1
205 GPa
53.7
15%
Chosen For
Vehicle

AISI 4130
(Chromoly)
0
205 GPa
63.1
25.5%

PROPERTIES:
Material Properties used in Roll Cage
Density (1000 kg/m3) : 7870
Poisson's Ratio
: 0.30
Elastic Modulus (GPa)
: 205
Tensile Strength (MPa : 634
Yield Strength (MPa)
: 365
Elongation (%)
: 27
Reduction in Area (%) : 48
Hardness (HB)
: 197

FINITE ELEMENT ANALYSIS OF

ROLLCAGE
DESIGN
USING
SOLIDWORKS 2013
All simulation of the space frame was done in the
SW2013 by considering a static structural analysis
of meshing type beam mesh and stimulated load
were applied on the critical points of the roll cage.
Before attempting to calculate the input loads, it
was necessary to determine what kind of obstacles
would be encountered during vehicle operation.
This was done by reviewing test and competition
videos of other SAE Baja vehicles on the internet.
This allowed the team to get a very broad sense of
what terrain the vehicle would be required to
overcome.
Force estimation for loading conditions

By Newtons IInd Law of motion

F = m.a
TEST MASS
GRAVITATIONAL STIMULATED
OF
ACCELERATION LOAD
VEHICLE

Where,
F= Force, m = mass of vehicle, a = acceleration
For Front impact analysis (Assumed G factor = 3.6)
Ff = 280kg x 3.6 x 9.81 m/s2
Ff= 9888.48 N
Hence force was taken to be 9890 N for FRONT
IMPACT TEST.

Results
Name

Min

Max

Stress

0 N/mm^2 (MPa)
Element: 38

163.978 N/mm^2 (MPa)

Element: 506

Displacement

0 mm Node: 35

Factor of Safety

2.22591
Node: 516

5.87726 mm
Node: 412
1e+016
Node: 42

For Rear impact analysis (Assumed G factor = 3.6)

F= 280kg x 3.6 x 9.81 m/s2
Fr= 9888.48 N
Hence force was taken to be 9890 N for REAR
IMPACT TEST.

Results
Name

Min

Max

Stress

0 N/mm^2 (MPa)
Element: 25

Displacement

0 mm
Node: 27
2.34119
Node: 119

155.904
N/mm^2
(MPa)
Element: 566
8.67686 mm
Node: 39
1e+016
Node: 27

Factor of Safety

For Side impact analysis (Assumed G factor = 3.2)

F= 280kg x 3.2 x 9.81 m/s2
Fs= 8789.76 N
Hence force was taken to be 8790 N for SIDE
IMPACT TEST.

Results
Name

Min

Max

Stress

0 N/mm^2 (MPa)
Element: 571

Displacement

0 mm
Node: 60
1.91237
Node: 502

190.862 N/mm^2
(MPa)
Element: 492
4.61364 mm
Node: 454
1e+016
Node: 581

Factor of Safety