Design and Analysis of Structure of Roll Cage for SUPRA SAE

This study aims to design, develop and fabricate a roll cage, in accordance with the SAE. A roll cage is a skeleton of an All-Terrain Vehicle (ATV). The roll cage is the Structural base which protects the occupant in case of impact and roll over incidents. A roll cage is a specially engineered and constructed frame built in the passenger compartment of a vehicle to protect its occupants from being injured in an accident, particularly in the event of a rollover. The main objective of the project to generate the CAD model of roll cage structure, to perform design and analysis of roll cage structure using FEA and to increase the product quality. Nowadays, most of the components of vehicle are in the stage of replacing with Steel and aluminium materials. This is due to the properties of material that can be designed freely to hold the load from any direction. Its light-weight property makes it possible to enlarge the performance of the car while maintaining low weight. On the basis of objective, data accumulated and design calculations the CAD model of the roll cage was design using Solidworks. After CAD modelling the Finite Element Modelling and Finite Element Analysis was carried out by using HYPERMESH and Nastran to validate the Designed CAD model. The linear static analysis results shows that the stresses are well within the safe limit, hence the design is safe.