DESIGN AND CRASH ANALYSIS OF A ROLLCAGE FOR FORMULA SAE RACE CAR

Abstract

The objective of this thesis is to analyze the design of the Formula SAE roll cage both analytical and by numerical methods. This analysis is based on the dynamic loads experienced by the roll cage under normal driving conditions, along with the torsional stiffness of the roll cage. A roll cage which is torsionally stiff enables a desirable roll moment distribution to be achieved for good handling balance. A roll cage which can absorb high energy impacts whilst controlling the rate of deceleration will increase the likelihood of drivers surviving a crash without injury. This work describes how a common model of the roll cage is developed using catia v5 and Hyper Mesh to allow both linear and non-linear Finite Element Analysis to be performed by LS-DYNA software. The results from this analytical calculations will be used in future designs of Formula SAE roll cage, with the recommendations made that the future design incorporate stressed mild steel and carbon-fiber skins on a tubular space frame. This is in preparation for a future semi-monocoque design. Improvements for the testing procedures include a need for a lighter and more accurate car swing setup, along with a more rigid torsional test.