|| Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774

INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH

AND ENGINEERING TRENDS

DESIGN AND STRUCTURAL ANALYSIS OF BAJA FRAME

WITH CONVENTIONAL AND COMPOSITE MATERIALS
Mr. PENUGULA DAVID RAJA RAO1 , Mr. CH. NARESH2, Mr.B S S PHANISANKAR3

1
M.Tech Student, Dept. of Mechanical Engineering, Bonam Venkata Chalamayya Institute of Technology & Science,
Andhra Pradesh
2
Assistant professor, Dept. of Mechanical Engineering, Bonam Venkata Chalamayya Institute of Technology & Science,
Andhra Pradesh
3
Assistant professor, Head of the Dept. of Mechanical Engineering, Bonam Venkata Chalamayya Institute of Technology &
Science, Andhra Pradesh
1
[email protected]

Abstract: An all-terrain vehicle (ATV), also known as a quad, quad bike, three-wheeler, or four-wheeler, is defined by
the American National Standards Institute (ANSI) as a vehicle that travels on low pressure tires, with a seat that is
straddled by the operator, along with handlebars for steering control. An ATV that abides by certain rule sets that are
devised by the SAE for a competition is known as BAJAS. BAJA SAE is an intercollegiate competition organized by
Society of Automotive Engineers (SAE) to design, build and race off-road vehicles. Chassis is an important part of the
BAJA vehicle that supports body and other different parts of the vehicle. It also surrounds and protects the occupant in
case of impact and roll over incidents and also gives the aesthetics of the vehicle. These vehicles are designed to run and
perform on any surface irrespective of the ground conditions. The design structure of an ATV solely depends upon it
roll-cage. As an ATV is an experimental vehicle the design procedure of its roll-cage plays a critical role to give
maximum possible strength while keeping the weight minimum. Roll cage of an ATV also absorbs various impacts
during an event or in test runs. The aim of the project is design of Roll cage using the CATIA software and analysis is
using the ANSYS software. We select two types of analysis in this project one is the static load condition and another
one is the modal analysis for calculating natural frequencies of different modes, finally finding out the stresses, strains,
and deformations in different cases such as front impact, side impact, rear impact by using the different materials (AISI
1018, AISI 4130, EGLASS EPOXY, CARBON FIBER) and finally concluding the material which is optimum for the
Roll cage based on the values.

pplication. ------------------------------------------------------ -------------------------------------------------

masses inside the car – Sprung and the Un-sprung mass. All
I INTRODUCTION
the mass of other subsystem components that is damped by
1 Baja Vehicle the spring is called as the sprung mass. Generally the sprung
The BAJA SAE is an event for the undergraduate students of mass must be great than that of the un-sprung mass.
engineering, organized by the Society of Automotive
Engineers. The event organized in the name of Mini-BAJA
competition. It serves as a platform for young engineering
students to showcase their skills by designing, fabricating and
validating a single seater off road vehicle and acquire a real-
life experience while overcoming obstacle and challenges .A
vehicle chassis, also called as Rollcage is the main
supporting structure of a BAJA SAE vehicle on which all
other components are mounted.
Frame of a vehicle is act like a skeleton it holds
all the important component of a automobile like engine,
steering systems, suspension, drive line, differential and all
the essential components which constitute together to form a
chassis. Chassis Frame must be stiff enough to withstand all
the forces and loads acting on it statically and dynamically
and forces like shock, twist and vibration. two types of
FIGURE 1 BAJA SAE VEHICLE

WWW.IJASRET.COM 23
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
 Loads due to the camber, side wind, cornering force
while taking a turn, which result in lateral bending
of side members
 Loads due to wheel impact with road obstacles may
cause that particular wheel to remain obstructed
while the other wheel tends to move forward,
distorting the frame to parallelogram shape
 Engine torque and braking torque tending to bend
the side members in vertical plane
 Impact loads during a collision
II. LITERATURE REVIEW
A vehicle chassis, also called as Rollcage is the main
supporting structure of a BAJA SAE vehicle on which all
other components are mounted. The main function of a chassis
is to support the vehicle's mechanical components and deal
with static and dynamic loads, without undue deflection or
distortion. It should be designed in an ergonomic and strong
FIGURE 2 ATV BAJA SAE
effective manner at optimum cost and weight for rough terrain
Following are the major points which were considered for purposes. In current scenario available are overdesigned i.e.
Designing the off road vehicle: their structural rigidity and sturdiness are more than
1. Endurance requirement. This leads to increase in weight and cost of
2. Safety and Ergonomics. manufacturing.
3. Market availability. Jonathan Hastie’s [1] analysis allowed the addition of three
4. Cost of the components. important and key structural components to help the vehicle
5. Standardization o Safe engineering practices with stand front and side impacts as well as the forces due to
the loading of the shock mounts. In this analysis it was found
1.2 ELEMENTS OF ROLL CAGE:
that design was failing in Roll Over, the findings from the
1.2.1 PRIMARY MEMBERS
finite element analysis and the actual failure have allowed us
 Rear Roll Hoop (RRH) to integrate a solution to this problem into their design from
 Roll Hoop Overhead Members (RHO the beginning.
 Front Bracing Members (FBM)
Smita, C.Saddu [4] et. al Weight reduction is now day’s main
 Lateral Cross Member (LC)
issue in the automobile industry. Reducing weight while
 Front Lateral Cross Member (FLC)
increasing or maintaining strength of product is getting to be
1.2.2 SECONDARY MEMBERS highly important. The automobile industry has shown
 Lateral Diagonal Bracing (LDB) increasing interest in the replacement of steel spring with
 Lower Frame Side (LFS) composite leaf spring due to high strength to weight ratio.
 Side Impact Member (SIM) Advanced composite materials offer significant advantages in
 Fore/Aft Bracing (FAB) strength, stiffness, high natural frequency and light weight
 Under Seat Member (USM) relative to conventional metallic materials. This paper
 All Other Required Cross Members describes the analysis of steel and composite material leaf
spring. Then these results are compared with that of the
1.3 LOADS ON THE CHASSIS FRAME
experimental results. Juvvi Siva Nagaraju
The chassis frame in general are is subjected to the
Sandip Godse D.A.Patel[ 6 ] et. Al Chassis is a major
following loads:
component in a vehicle system. This work involved static
 Weight of the vehicle and the passengers, which analysis to determine key characteristics of a chassis. The
causes vertical bending of the side members static characteristics include identifying location of high
 Vertical loads when the vehicle comes across a stress area. Mathematical calculations were carried out to
bump or hollow, which results in longitudinal validate the static analysis.
torsion due to one wheel lifted (or lowered) with K.Rajasekar, R.SaravananP[7] et. Al Chassis is the most
other wheels at the usual road level important structural member in the On-Road vehicles. In

WWW.IJASRET.COM 24
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
order to overcome more failure in the chassis structure and for making it better and light weight.
ensure the safety, the variable section chassis structure has to 3. Using variety of material to make better chassis for
be designed based on the variable loads along the length of various applications and mostly for racing purpose.
the vehicle. The present study reviewed the literature on
4. Practice Engineering knowledge with budgeting for
chassis design and presented the findings in the subsequent
making Cost effective chassis.
sections.
3.4 METHODOLOGY
ROLLCAGE: The chassis or Space frame of the mini Baja
is called as roll cage. The roll cage serves many critical Design of any component is consists of three major
functions that include linking the power train, control, and principles:
suspension systems together. It must also be capable of 1. Optimization
protecting the driver and crucial components of the vehicle
2. Safety
while having an impact towards rigid structures or accidents
with other vehicles. 3. Comfort

III PROJECT OVER VIEW Step 1: Collecting information and data related to Baja
vehicle chassis
3.1 DESIGN OBJECTIVES OF CHASSIS ARE:-
Step 2: A fully parametric model of the Baja vehicle chassis
1) To get knowledge of BAJA Chassis Design for beginner in
is created in catia software.
stepwise manner so to avoid unnecessary thing and focuses
on competition. Step 3: Model obtained in igs is analyzed using ANSYS 16.5
(work bench) to obtain stresses, strain, deformation etc.
2) Focusing area of analysing Software to get desirable
result. Step 4: Front, rear and side impact manual calculations are
done
3) To make use of welding alternative of hydraulic press.
Step 5: Finally, we compare the results obtained from
4) Use of welding Principle effectively without increasing
ANSYS and compared different materials.(CARBON
weight of chassis and make it simple.
FIBER, AISI1018, E-GLASS, AISI 4130)
3.2 PROBLEM IDENTIFICATION:
3.5 FUNCTIONS OF THE FRAME
Design and carry out Finite Element Analysis and Rollover
1. To carry load of the passengers or goods carried in the
Simulations for an off road vehicle chassis with suitable tube
body.
diameter, wall thickness and material to withstand different
load conditions to have a high Factor of safety, least weight 2. To support the load of the body, engine, gear box etc.,
and reasonable cost. Weight reduction is now the main issue 3. To with stand the forces caused due to the sudden braking
in automobile industries. Because if the weight of the vehicle or acceleration.
increases the fuel consumption increases. At the same time as
4. To with stand the stresses caused due to the bad road
the weight of the vehicle increases the cost also increases
condition.
which becomes a major issue while purchasing an
automobile. For example if we take frame of BAJA vehicle 5. To with stand centrifugal force while cornering.
frame. For these reasons, fiber composites have emerged as a 3.6 MATERIAL PROPERTIES
major class of structural material and are either used or being
considered as substitutions for metals in many weight-critical
components in aerospace, automotive and other industries.
High damping capacity of composite materials can be
beneficial in many automotive applications in which noise,
vibration, and hardness is a critical issue for passenger
comfort.
3.3 SCOPE OF PROJECT:
1. Baja vehicle is the wide popularity as it is suitable for most
of people to make their own playing race car as well as
working car by using their knowledge and competition with
other in racing.
2. Making advance engineering Knowledge to use at chassis FIGURE 3MATERIAL PROPERTIES

WWW.IJASRET.COM 25
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
3.7 DESIGN OBJECTIVES: members is circular as it would bear more strength than beam
1. Creation of a cad model of the structure. section with ability to withstand torsional stresses also.

2. Generation of mesh. Attributes values

3. Application of the loads & constraints in depending. Length of the vehicle 1725mm
4. Solution of the respective test Determination of the stress
Width of the vehicle 817mm
values and deformation forces.
5. Modification of Cad- design. Height of the vehicle 900mm
REAR IMPACT: In real conditions during rear impact, Weight of the vehicle 249.5kgs
another vehicle is going to hit vehicle on its rear part. The including driver
analysis conditions and results are shown in Figures
Weight of the vehicle frame 38 kgs
CALCULATIONS:
From work energy principal Thickness of the tube 2.5
Work done = change in kinetic energies
W = (0.5 × M × vfinal 2 - 0.5 × M × vinitial 2 ) Inner diameter 25mm
│W│ = │- 0.5 × M × (Vinitial) 2│ Outer diameter 30mm
=│- 0.5 × 220 × 16.672 × 16.672│
= 30575.11 Nm Ground clearance 320mm
Now,
Work done = force × displacement= F × s
S = impact time × Vmaximum
= 0.3 ×16.67
= 5.001 m
So, from (1) we get,
F = W/ s = 30575.11 / 5.001
= 6112.3≈ 6500 N (3G’s)
SIDE IMPACT: In real conditions during rear impact, Figure 4 SIDE VIEW OF THE FRAME
another vehicle is going to hit vehicle on its side members.
IV DIMENSIONS AND DESIGN PROCEDURE IN
The analysis conditions and results are shown in figures.
CATIA:
CALCULATIONS:
From work energy principal, Create the frame in wire frame and surface design workbench
Work done = change in kinetic energies using planes, points, lines after go to the part design
W = (0.5 × M × vfinal 2 - 0.5 × M × vinitial 2 ) workbench create the diameter of inner and outer circles as
│W│ = │- 0.5 × M × (Vinitial) 2│ per the above dimensions now go to the rib option apply each
=│- 0.5 × 220 × 16.672 × 16.672│ and every lines as shown below figure
= 30575.11 Nm
Now,
Work done = force × displacement= F × s
S = impact time × Vmaximum
= 0.3 ×16.67
= 5.001 m So, from (1) we get,
F = W/ s = 30575.11 / 5.001
= 6112.3 ≈ 6500 N (3G’s)
3.8 dimensions of the rollcage baja vechicle:
The design of the roll cage in any condition must always FIGURE 5 ISOMETRIC VIEW
ensure enough clearances from members for safety and free V ANALYSIS PROCEDURE IN ANSYS:
movement of the driver. The diameter of the primary member
Designed component in catia workbench after imported into
is 30 (mm) with thickness of 1.65 (mm) and that of the
ansys workbench now select the steady state thermal analysis
secondary members is 25 (mm) The cross-section of the
.

WWW.IJASRET.COM 26
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
1.ENGINEEERING MATERIALS (MATERIAL 6.1.1FRONT IMPACT ANALYSIS OF AISI 1018
PROPERTIES). MATERIAL:
2. CREATE OR IMPORT GEOMENTRY.
3.MODEL(APPLY MESHING).
4.SET UP(BOUNDARY CONDITIONS)
5.SOLUTION
6.RESULTS
5.1 STATIC STRUCTURAL ANALYSIS
The static structural analysis calculates the stresses,
displacements, strains, and forces in structures caused by a
load that does not induce significant inertia and damping
effects. Steady loading and response conditions are assumed; Figure 7 VON-MISSES STRESS OF AISI 1018
that the loads and the structure’s response are assumed to MATERIAL
change slowly with respect to time. A static structural load 6.1.2FRONT IMPACT ANALYSIS OF AISI 4130
can be performed using the ANSYS WORKBENCH solver. MATERIAL:
The types of loading that can be applied in a static analysis
include.
5.2 MODAL ANAYSIS:
In modal analysis free natural vibration frequencies of roll
cage frame was found out for the first 6 modes keeping the
suspension members and the attached member of the mounts
constrained. All the modes that were found out were rigid
body mode.Vibrations can also be induced due to the bumps
or road but as their intensity would be low it is not
considered. Although the bumps and vibration due to
reciprocating engine .
Figure 8 VON-MISSES STRESS OF AISI 4130
MATERIAL
6.1.3FRONT IMPACT ANALYSIS OF CARBON FIBER
MATERIAL:

Figure 6 MESH: NODES, ELEMENTS:

VI RESULTS AND DISCUSSIONS
6.1 STATIC ANALYSIS RESULTS:
This analysis is performed to find Structural parameters such
as Stresses, Strains, Deformation, Here we observed results Figure 9 VON-MISSES STRESS OF CARBON FIBER
on two materials namely (AISI 1018, AISI 4130, EGLASS MATERIAL
EPOXY, CARBON FIBER).

WWW.IJASRET.COM 27
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
6.1.4 FRONT IMPACT ANALYSIS OF EGLASS FIBER 6.2.3REAR IMPACT ANALYSIS OF CARBON FIBER
MATERIAL: MATERIAL:

FIGURE 10 VON-MISSES STRESS OF E-GLASS FIGURE 13 VON-MISSES STRESS OF CARBON

FIBER MATERIAL FIBER MATERIAL
6.2 REAR IMPACT: 6.2.4 REAR IMPACT ANALYSIS OF E-GLASS FIBER
6.2.1 REAR IMPACT ANALYSIS OF AISI 1018 MATERIAL:
MATERIAL:

FIGURE 14 VON-MISSES STRESS OF E-GLASS

FIGURE 11 VON-MISSES STRESS OF AISI 1018
FIBER MATERIAL
MATERIAL
6.3 SIDE IMPACT
6.2.2 REAR IMPACT ANALYSIS OF AISI 4130
MATERIAL: 6.3.1 SIDE IMPACT ANALYSIS OF AISI 1018
MATERIAL:

FIGURE 15 VON-MISSES STRESS OF AISI 1018

FIGURE 12 VON-MISSES STRESS OF AISI 4130
MATERIAL
MATERIAL

WWW.IJASRET.COM 28
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
6.3.2 SIDE IMPACT ANALYSIS OF AISI 4130 6.4 MODAL ANALYSIS OF AISI 4130 MATERIAL:
MATERIAL:

Figure 19 MODE 1 OF AISI 4130 MATERIAL

6.5 MODAL ANALYSIS OF CARBON FIBER
MATERIAL:
FIGURE 16 VON-MISSES STRESS OF AISI 4130
MATERIAL
6.3.3SIDE IMPACT ANALYSIS OF CARBON FIBER
MATERIAL:

Figure 20 Mode 1 OF CARBON FIBER MATERIAL

6.6 GRAPHS
6.6.1 FRONT IMPACT:
From below figure, we can observe that in case of equivalent
FIGURE 17 VON-MISSES STRESS OF CARBON (von-misses) stress, Total deformation, shear stress, strain
FIBER MATERIAL BAJA CHASSIS .Apply front impact load on chassis fixed
6.3.4 SIDE IMPACT ANALYSIS OF E-GLASS FIBER back end and it is made up of (AISI1018, AISI 4130,
MATERIAL: Carbon fiber, E-Glass epoxy) carbon fiber is Observed to
have least (von-misses) stress, Total deformation, shear
stress, strain comparison with remaining materials including
the present material is AISI 1018 material as shown below
figure.

FIGURE 21 VONMISSES STRESS OF FRONT

FIGURE 18 VON-MISSES STRESS OF E-GLASS IMPACT
FIBER MATERIAL

WWW.IJASRET.COM 29
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
6.6.2 REAR IMPACT:
From below figure, we can observe that in case of equivalent
(von-misses) stress, Total deformation, shear stress, strain
BAJA CHASSIS .Apply Rear impact load on chassis fixed
Front end and it is made up of (AISI1018, AISI 4130, Carbon
fiber, E-Glass epoxy) carbon fiber is Observed to have least
(von-misses) stress, Total deformation, shear stress, strain
comparison with remaining materials including the present
material is AISI 1018 material as shown below figure. FIGURE 24 MODAL ANALSYSIS OF AISI 4130
MATERIAL
VI CONCLUSION
We had successfully analyzed the roll cage structure for its
strength against the collision from front, rear as well as side.
This project thoroughly deals with various load analysis on
BAJA roll cage and optimization has been achieved by
reducing the weight of the roll cage. Roll cage designed is
perfect for use in BAJA SAE Parameters taken in rule book.
FIGURE 22 VONMISSES STRESS OF REAR IMPACT Perhaps the biggest advantage of composites is their high
strength-to-weight ratio. As per the above experiments we
6.6.3 SIDE IMPACT:
can conclude that Carbon fiber material is best for the Frame
From below figure, we can observe that in case of equivalent and AISI 4130 is also suitable when we prefer conventional
(von-misses) stress, Total deformation, shear stress, strain materials. Analysis performed using finite element method
BAJA CHASSIS .Apply Right side impact load on chassis was successfully and carried out on the Rollcage. Hence the
fixed at left end and it is made up of (AISI1018, AISI 4130, chassis design is safe to manufacture with composite material
Carbon fiber, E-Glass epoxy) carbon fiber is Observed to (Carbon Fibre) when compared to other specified materials.
have least (von-misses) stress, Total deformation, shear
REFERENCES
stress, strain comparison with remaining materials including
the present material is AISI 1018 material as shown below [1] S. J. P. J. V. K. A. a. A. P. Aru, “DESIGN, ANALYSIS
figure. AND OPTIMIZATION OF A MULTI- TUBULAR SPACE
FRAME,” International Journal of Mechanical and
Production Engineering Research and Development
(IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001 Vol.
4, Issue 4, Aug 2014, 37-48© TJPRC Pvt. Ltd.
[2] N. Noorbhasha, “Computational analysis for improved
design of an SAE BAJA frame structure,” UNLV Theses,
Dissertations, Professional Papers, and Capstones. Paper 736,
12-2010.
[3] D. Raina, R. Gupta, R.K.P., “Design and Development
for Roll Cage of All- Terrain Vehicle,” International Journal
for Technological Research in Engineering (IJTRE) Volume
2, Issue 7, March-2015 ISSN: 2347-4718 .
[4] SAE-BAJA, Rule book 2019 https://www.bajasaeindia.
org/pdf/BAJA-SAEINDIA-Rulebook-2019-Rev.00.pdf.
[5]. Rulebook BAJA SAE INDIA 2017.
FIGURE 23 VONMISSES STRESS OF SIDE IMPACT [6]. https://bajasaeindia.org
6.4 MODAL ANALYSIS OF AISI 4130 MATERIAL: [7]. Chris Bennett, Anthony McClinton, Robin McRee and
Modal analysis graph is the study of the dynamic properties Colin Pemberton “SAE BAJA mini frame analysis”
of systems in the frequency domain as shown below figure in [8]. Deepak Raina, Rahul Dev Gupta, Rakesh Kumar
different modes shows the total deformation and frequencies Phanden “Design and Development for Roll Cage of All
of AISI 4130 & Carbon fiber.

WWW.IJASRET.COM 30
 || Volume 5 || Issue 7 || July 2020 || ISSN (Online) 2456-0774
INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH
AND ENGINEERING TRENDS
Terrain Vehicles”. International Journal for Technological
Research In Engineering (IJTRE) Volume 2, Issue 7, March-
2015 ISSN: 2347-4718
[9]. Jonathan Hastie “Mini Baja Vehicle Design Optimization
[10]. Amal Tom Kumbiluvelil and Abu Thomas Cherian
“Designing and Analysis of Roll Cage of an ATV”. Int.
Journal of Engineering Research and Applications, ISSN:
2248-9622, Vol. 3, Issue 5, Sep-Oct 2013, pp.1871-1873
[11]. Upendra S. Gupta, Sumit Chandak, Devashish Dixit,
Harsh Jain “Design & Manufacturing of Roll cage for all-
Terrain Vehicle – Selection, Modification, Static & Dynamic
Analysis of Roll Cage for an ATV Vehicle”. International
Journal of Engineering Trends and Technology (IJETT) –
Volume 20 Number 3 – Feb 2015.
[12]. Nagurbabu Noorbhasha, Computational Analysis for
Improved Design of a SAE BAJA Frame Structure, Master of
Science thesis, Howard R. Hughes College of Engineering,
University of Nevada, Las Vegas, NV

WWW.IJASRET.COM 31