International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 10 Issue: 08 | Aug 2023
p-ISSN: 2395-0072
www.irjet.net
Design optimization and analysis of ATV Roll Cage D Nagendra Varma1, V Tharun Krishna2, M S Srikar3 1,2,3Undergraduate Students, Department of Mechanical Engineering, GITAM Deemed to be University,
Visakhapatnam, Andhra Pradesh, India ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - The purpose of this paper is to design a roll cage. Here we will be going through the step-by-step procedure involved in designing a roll cage, including material selection, geometric design, and analysis. We will also be taking a look at all the calculations involved in the design and optimization of the roll cage.
1. INTRODUCTION The design of the roll cage heavily influences the ergonomics and appearance of the entire vehicle. The weight reduction in the chassis is crucial to having a dynamically stable vehicle with a low center of gravity while considering all mechanical design and safety considerations. The roll cage needed to be constructed with many factors in mind because it plays such a significant role. The roll cage must have the best possible design that balances its weight and strength. The AllTerrain Vehicle (ATV) Roll cage design under investigation in this research is based on SAE Standards. The document also includes elaborate 3D sketching and weldments design.
Fig. 1 The roll cage has to be designed considering the following goals and requirements. 1. BAJA SAE rules 2. Driver safety 3. Driver ergonomics 4. Proper weight biasing 5. Proper orientation & installation of subassemblies.
2. Design Overview
6. Ease of manufacturing
The roll cage of an ATV is the main outer structure that provides protection to the driver during any crash or rollover. The roll cage also acts as the vehicle's main frame, providing mountings for components like the suspension system, drive system (engine, front differential, gearbox), steering system, etc. The design of the roll cage has been carried out in SOLIDWORKS 2021, with the ergonomics check being done in Catia V5.
3. Design and optimization The design process of the roll cage can mainly be divided into three steps which are 1. 2. 3.
First, some initial constraints of the vehicle were fixed, which included track width, wheelbase, ground clearance, wheel radius steering rack length, rack position, etc., which helped us finalize the suspension points using Lotus Shark software. This was done following an iterative process trying different combinations to obtain the best possible dynamic results for the vehicle; the finalized suspension geometry can be seen in Fig [1].
Material selection Structure design Analysis
This is an iterative process wherein if we are not satisfied with the results, we repeat the process.
3.1 Material Selection The selected material must satisfy the requirements of the BAJA SAE Rule book. According to the rule book, the roll cage must consist of 2 different types of members, i.e., Primary and secondary members. For primary members, the rules are • Circular steel tubing with an outside diameter of 25 mm (1.0 in) and a wall thickness of 3 mm (0.120 in.) and carbon content of at least 0.18%.
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