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Uploaded: 2023-07-26
Duration: 2 min 31 s
Description: CAD FEA Prototype Model refinement Final m odel Rule Design process.

CAD FEA Prototype Model refinement Final m odel Rule Design process. 

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CAD FEA Prototype Model  refinement Final m odel	 Rule Design process

Rule Book Comparison Rulebook  Reference Parameters Allowable Value (mm) Designed  Value(mm) B.3.2.16 Primary Member (D o / T) 25 / 3 29.2 / 1.65 B.3.2.3 Secondary Member (D o / T) 25.4 /0.89 25.4 / 2.5 B.3.2.5 LC Min Length 203.5 580 ALC Min Length 457 600 B.3.2.6 RRH Inclination 20˚ 10˚ Width Of RRH, At 686 Mm  Above Seat Bottom 736 737 Min Width Of RRH, At 14  Inch Above Seat Bottom 812.8 820.4 B.3.2.7 Intersection Of LDB And RRH (Top & Bottom) 127 (5”) 127 B.3.2.8 Min Distance CR And CL 305 400

Design targets To   enhance   performance  and    ensure   driver s afety. Fortified   Structure. Improved    Driver   Vision Maximum  hand reach Envelope. Design  c onsi d e r a tions  b as e d on   95% male   population. Reduced   weld   joints. Decrease   the   wheel   base.

Characteristics Number   of   welded   Joints   –   52 Serviceability   -  Materials   are  able   to   be   removed,   reworked  and    repaired   under   certain   period   of   time .

ROLL   CAGE   DESIGN   METHODOLOGY   -   ERGONOMICS

May be an image of racing vehicles, car, carriage, dune buggy and poster

Rula   Score         Parameter Score Posture Static Arms-supported Yes Arms-working   across   mid   plane Yes Upper   arm 2 Lower   arm 1 Wrist 3 Neck 2 Trunk 1 Legs 2 Muscle   load 1 Rula   Score 3

During the welding operation, a fixture holds the tubes in place.  It makes sure the joints are in the proper location and alignment,       which lowers the            possibility of deformation and raises the level of overall weld quality.  This is especially important for building a sturdy and trustworthy roll cage.

Fr ont a l Impact F = ma/t 6000 N 4G. F = W/s 3000 N 3G Roll Over. 

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Fr ont a l   Impact  F   = ma/t 6000 N 4G

Proposed   FOS 1 - 3 Deformation   (mm) 1   -   10 CONSTRAINTS Front Rear Side Rollover Rear    Su s pen s ion   Mount Front   Su s pen s ion   Mount Su s pen s ion   Mount Su s pen s ion  M ount

S ta ti c   Ana l y s i s   P aramete r s Analysis   Type 3D   Beam Mesh   Size 7  mm No.   of   nodes 1 324903 Solver Ansys   Workbench   2022 R1 Element Improper    C onnection Error  in    results   up    to   20   % Quality Free   Nodes/   3D   Elements

Composition Risks/Merits AISI   4130   (%) Mn   <   0.30% Lead  to cracking    and internal    porosity   (R) 0.4   –   0.6 High   %   of   S   &   P Solidification cracking   in   HAZ   (R) S   –   0.04 P   –   0.035 High   Carbon   % Reduces   Weldability   (R) 0.28   –   0.33 Presence   of   Mo    &   Cr   % St r e n g t h e n ing   Agents   (M) M o-   0.1 5 -0.25 Cr   -   0.80-0.10

Force FOS Stress   (MPa) Deformation (mm)

AISI 1018 VS AISI 4130
CARBON CONTENT
BENDING STIFFNESS
BENDING STRENGTH
TENSILE STRENGTH
50
100
DAISI 1018
D Aisl 4130
150

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