Explicit Dynamic Frontal Crash Test Analysis Of FSAE Roll Cage Using AISI 4130 And Docol R8 Steel

This study investigates the crashworthiness performance of a FSAE roll cage subjected to frontal impact using explicit dynamic simulation. Two high-strength materials, AISI 4130 chromoly steel and Docol R8 advanced high- strength steel, were evaluated. The roll cage geometry was modelled using SolidWorks and imported into ANSYS Explicit Dynamics for frontal crash simulation at an impact velocity of 8 m/s against a rigid wall boundary condition. Key performance indicators such as total deformation, equivalent von-Mises stress distribution, plastic strain, and energy absorption characteristics were analysed. A comparative study between both materials was conducted to determine structural safety performance and weight optimization potential. Results indicate that Docol R8 provides improved strength-to-weight performance compared to AISI 4130, demonstrating its suitability as an alternative roll cage material for Formula Student vehicles.