Roll Cage Analysis for E-ATV Using Finite Element Method

This paper presents an analysis of a rear-braced style roll cage for an Electric All-Terrain Vehicle (E-ATV) buggy, emphasizing its crucial role in ensuring vehicle safety and structural integrity. The roll cage, along with the chassis, forms the structural base for integrating and mounting critical subsystems, such as steering, suspension, axle, and gearbox, differential. Our prime goal is to design and develop a roll cage that is both lightweight and highly rigid to protect the driver effectively. Additionally, we aim to construct an optimized roll cage with the appropriate material and needs to achieve the optimum factor of safety for E-Baja Buggy. We selected Chromoly for its exceptional ultimate tensile strength and yield strength. When constructing a roll cage, we utilized two types of materials it is primary and secondary. The primary and secondary member cross-sections are fixed according to the Baja SAEINDIA Rule book as per the rules. Here, Finite Element Analysis (FEA) methods are employed to determine the stress distribution and deformation caused by forces. These forces act in various directions, which can lead to deformation and crack initiation on the member. The study includes torsional analysis and crash simulations for frontal, rear, and side impacts, as well as rollover scenarios. These designs and analyses are performed using Solid Works 2022 and Ansys Workbench 2020R1 to accurately simulate the structural response of the roll cage. The design follows the guidelines set by the Baja SAEINDIA Rule book. The findings highlight the critical stress areas and potential points of failure, allowing for design optimization to improve performance and safety.