Design and Structural Evaluation of a Roll Cage for Baja All-Terrain Vehicles

Abstract

The roll cage is a critical structural element of an all-terrain vehicle (ATV), providing essential rigidity and enhancing occupant safety during off-road operation. This study presents the design and structural evaluation of an ATV roll cage, focusing on CAD modeling, finite element preprocessing, and static structural analysis. The roll cage geometry was developed using Creo to satisfy key requirements such as strength, weight efficiency, and compatibility with the vehicle chassis. The completed model was then discretized using Hyper mesh, where appropriate meshing was applied to ensure reliable numerical results. Static structural analysis was carried out using the Opti Struct solver to evaluate stress distribution, deformation behavior, and potential failure regions under representative loading conditions, including gravitational effects and external impact loads encountered during off-road use. The results confirmed that the roll cage design meets safety and performance criteria, with factor of safety values maintained within acceptable limits, supporting its suitability for demanding off-road environments.