Roll Cage Analysis

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Roll Cage Analysis

• Mario Russo - James Kokkinos

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Purpose of Cage

• To provide protection
• Add structural strength and rigidity

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Project Scope

• Model the Roll Cage in Strand7
• Different load cases and materials (Steel and
  Aluminium)
• Within design material strength limits
• Complied with safe deflection limits

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The Roll Cage
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Method of Analysis

• A typical design adapted to Ford Focus.
• Front and Base plate thicknesses
• Realistic loads
• Support Reactions
• Model modified to suit objectives

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Materials Beams
High Strength Aluminium (350 MPa)
High Strength Steel (500 MPa)
Outside Diameter 70 mm Wall Thickness 8
mm Total Beam Weight 95 kg
Outside Diameter 70 mm Wall Thickness 6
mm Total Beam Weight 214 kg
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Materials - Plates
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Load Case 1 - Front Impact
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Load Case 2 - Side Impact
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Optimisation of Design

• Iteratively modified tube and plate thicknesses
• Achieve design deflections without reaching
  material yield stresses
• Minimise cage weight while remaining within
  limits

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Results
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Front Impact
Max Total Fibre Stress
Max Plate Stress (tension)
Critical Deflection
Max Plate Stress (compression)
Max Axial Stress
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Side Impact
Max Plate Stress (compression)
Max Axial Stress
Max Plate Stress (tension)
Critical Deflection and Max Total Fibre Stress
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Conclusions

• Was design satisfactory
• Which was the better design and why?
• What we learned from this analysis

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Thank You Questions?