MINI PROJECT
PHASE 2
IMPACT ANALYSIS ON ROLL CAGE
Submitted in partial fulfillment of the requirements of the degree of
Bachelor of Engineering
in
Mechanical Engineering
Submitted by
ARNAV APTE 9650
KUSHAL PATIL 9674
TEJAS PIRWARE 9677
MANAN BHANSALI 9652
Under the Guidance
Dr. Ketaki Joshi
Department of Mechanical Engineering
Fr. Conceicao Rodrigues College of Engineering
Bandra, Mumbai – 400050
University of Mumbai
2022-2023
CERTIFICATE
This is to certify that the Mini Project - 1A stage 1 report entitled
Regenerative braking is a bonafide work of Arnav Apte 9650, Kushal Patil 9674, Tejas Pirware 9677, Manan
Bhansali 9652 submitted to the University of Mumbai in partial fulfillment of the requirement for the award
of the degree of Bachelor of Engineering in Mechanical Engineering.
Dr. Ketaki Joshi
Guide
Dr. B T Patil Dr. S S Rathod
Head of Department Principal
Approval Sheet
Mini Project - 1A Stage 1 Report Approval for B. E.
This mini project-1A stage 1 report entitled Project Title by Arnav Apte 9650,Kushal Patil 9674, Tejas Pirware
9677, Manan bhansali 9652 is approved for the partial fulfilment of award of Degree of Bachelor of
Mechanical Engineering.
Examiners
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I declare that this written submission represents my ideas in my own words and where others'
ideas or words have been included, I have adequately cited and referenced the original sources. I also
declare that I have adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I understand
that any violation of the above will be cause for disciplinary action by the Institute and can also evoke
penal action from the sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.
ARNAV APTE 9650
KUSHAL PATIL 9674
TEJAS PIRWARE 9677
MANAN BHANSALI 9652
____________________________
(Signature)
Date:
Abstract
The roll cage, a crucial piece of safety equipment in high-performance racing and off-road
vehicles, was the subject of our impact analysis, the findings of which are presented in this
research paper. This analysis's goal was to assess the roll cage's resistance to various impacts,
such as frontal and rear collisions, rollovers, and torsion. The advanced analysis software -
ANSYS was used to perform the simulations. The analysis' results shed important light on the
roll cage's functionality, including its capacity to disperse and absorb impact forces as well as
maintain structural integrity in the face of various impacts. The findings of this study can be
used to the design and development of roll cages in high-performance cars, thereby enhancing
safety of the driver.
CONTENTS
Sr. No. Topic Page No.
1. Introduction
2. Literature Review
3. Problem Definition
4. Methodology
5. Results and discussion
6. Conclusion
References
0.005235784
0.005363797
0.005521842
0.005742441
0.005984071
0.006279699
0.006645814
0.007024459
0.0074834
0.007942483
0.008491629
0.009179247
0.009821202
0.0107282
0.01165798
0.01290847
INTRODUCTION
Roll cages are a crucial part of modern automobile safety, especially in off-road and racing
applications. Roll cages shield the car's occupants in the event of an accident by absorbing and
distributing impact forces. It is essential to do extensive impact analysis testing on a roll cage to
determine how well it can survive different kinds of impacts. We offer the findings of an impact
analysis on a roll cage that took into account front and rear hits, roll-over, and torsion testing in
this research document.
SR.NO ANGLE OF COEFFICENT COEFFICENT CL/CD
ATTACK OF LIFT OF DRAG
1 -2 -0.25 0.0074 -33.8
2 0 0 0.0072 0
3 2 25 0.0073 34.2
4 4 0.499 0.008 62.4
5 6 0.748 0.0091 82.2
6 8 0.995 0.0106 93.9
7 10
8 12
9 14
10 16
Table No. 1 PLOTTED VALUES IN TABULAR FORMAT
LITERATURE REVIEW
1) Liu et al. (2013)from the given paper we understood the real need for a mesh and how mesh
density affects accuracy of results and time taken to compute the results……[1]
2) Abdullah et al. (2018 ) from the given paper we understood how to calculate the forces applied
in the various analysis….[2]
3) Laskey et al.(2022)from the given paper we understood how fixed supports are truly used
4) Maradey Lázaro et al. (2018)
5) Owens et al.(2006)we referred this paper to gain an idea in which format and what all
simulation results are to be used
PROBLEM DEFINITION
The roll cage given was constructed using solid works and will be analyzed using the analysis
software ANSYS
The analysis that will be done on the this roll cage are
Front impact
Rear impact
Roll over
Torsion
The main motive is to check whether there are any bends in the members of the roll cage or if
there are any abnormalities present in the roll cage
THE ROLL CAGE IS MADE OF AISI 4130 STEEL
Carbon content 0.3%
Density 7833 kg/m^3
Tensile yield strength 626
Tensile ultimate strength 806
METHODOLOGY
FRONT IMPACT ANALYSIS:
Calculations:
Initial velocity of the vehicle (u) = 60 Km/hr = 16.67 m/s
Final Velocity of the vehicle (v) = 0 Km/hr
Weight of the car (m) = 260 kg
Impact Time (t) = 0.15 s
So, acceleration is given by,
a = (v-u)/t
a = (0-16.67)/0.15
a = -111 m/s2
Negative Sign indicates that the car will decelerate
We get,
a = 11g
Now the forces will be,
F = 11 X m X g
F = 11 X 260 X 9.81
F = 28228.2 N
This force will be applied on the bumper and Rear suspension Mountings will be made
fixed.
REAR IMPACT ANALYSIS:
Calculations:
Initial velocity of the vehicle (u) = 60 Km/hr = 16.67 m/s
Final Velocity of the vehicle (v) = 0 Km/hr
Weight of the car (m) = 260 kg
Impact Time (t) = 0.15 s
So, acceleration is given by,
a = (v-u)/t
a = (0-16.67)/0.15
a = -111 m/s2
Negative Sign indicates that the car will decelerate
We get,
a = 11g
Now the forces will be,
F = 11 X m X g
F = 11 X 260 X 9.81
F = 28228.2 N
This force will be applied on the FAB(rear) members and the bumper will be made fixed.
ROLL OVER ANALYSIS:
Calculations:
Height of the cliff = 10 ft = 3 m
Weight of the car (m) = 260 kg
Impact time (t) = 0.15 s
Impact Force = Work done/displacement
Also, work done = K.E.
But, K.E. = -P.E.
1
X m X v2 = -m X g X h
2
v = (2 X g X h)
v = -(2 X 9.81 X (-3))
v = 7.73 m/s
1 1
Work done = K.E. = X m X v2 = X 260 X 7.732
2 2
Work done = 7767.88 Nm
Also, Displacement = velocity X time =7.73 X 0.15 = 1.16 m
Now, Impact force = Work done/displacement =7767.88/1.16 =6699.33 N
This force will be applied on the RHO, BLC and CLC members and all the suspension Mountings
will be made fixed.
TORSION ANALYSIS:
calculations:
Mass of the vehicle (m) =260 kg
For Torsional Impact, we have directly considered 2g-force
F=2XmXg
F = 2 X 260 X 9.81
F = 5101.2 N
An upward force to one of the front LFS member and downward force to other front LFS
member and Rear suspension Mountings are made fixed.
RESULTS AND DISCUSSION
FRONT IMPACT ANALYSIS:
Max Total deformation: 8.2299 mm
Max Directional deformation: 5.2175 mm
Max Equivalent stress: 405.74 MPa
Safety factor: 1.5
REAR IMPACT ANALYSIS:
Total deformation: 35.464 mm
Directional deformation: 3.3809 mm
Equivalent stress: 588.1 MPa
Safety factor: 1
ROLL OVER ANALYSIS:
Max Total deformation: 3.0021 mm
Max Directional deformation: 0.2567 mm
Max Equivalent stress: 214.67 MPa
Safety factor: 2.9
TORSION ANALYSIS:
Total deformation: 4.5496 mm
Directional deformation: 0.74709 mm
Equivalent stress: 299.8 MPa
Safety factor: 2
CONCLUSION
In this research document, we performed an impact analysis on a roll cage, which included front and
rear impacts, roll-over, and torsion testing. The results of our analysis revealed that reinforcement is
needed on the members of the roll cage in the area of front and rear impacts, as these tests showed
weaker results. However, the roll-over and torsion tests showed better results, indicating that the roll
cage is capable of withstanding these types of impacts.
Our findings suggest that the design of the roll cage needs to be optimized to improve its performance
in front and rear impact scenarios. The use of stronger and more robust materials or additional
reinforcements may be necessary to enhance the roll cage's ability to absorb and distribute impact
forces. However, the roll-over and torsion tests showed promising results, indicating that the roll cage's
design is effective in protecting occupants in these situations.
Overall, the results of our impact analysis highlight the importance of conducting rigorous testing to
evaluate the performance of roll cages, especially in high-performance racing and off-road applications.
By identifying areas of weakness and opportunities for improvement, we can continue to enhance the
safety of vehicles and protect drivers and passengers from potential accidents.
REFERENCES
1. https://www.simscale.com/docs/simwiki/fea-finite-element-analysis/what-is-fea-finite-
element-analysis/
2. Liu, Y., & Glass, G. (2013). Effects of Mesh Density on Finite Element Analysis 2013-01-1375
3. Abdullah, S. H. (2018). Computational Analysis for Optimization of Baja SAE Roll Cage. IJSRD-
International Journal for Scientific Research & Development, 6(04), 1395-1399.
4. Laskey, J. A. (2022). Impact Analysis of a Baja Roll Cage.
5. Maradey Lázaro, J. G., Esteban Villegas, H. S., & Blanco Caballero, B. J. (2018, November). Finite
element analysis (FEA) for optimization the design of a Baja SAE chassis. In ASME International
Mechanical Engineering Congress and Exposition (Vol. 52033, p. V04AT06A050). American
Society of Mechanical Engineers.
6. Owens, A. T., Jarmulowicz, M. D., & Jones, P. (2006). Structural Considerations of a Baja SAE
Frame (No. 2006-01-3626). SAE Technical Paper.
