Bremar Automotion - October 2015
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Motorsport Rollcages

FIA Technical List No. 35

We are pleased to announce that Bremar Automotion was recently granted approval from CAMS and the FIA to certify motorsport rollcages using Finite Element Analysis (FEA). Only approved bodies that are on the FIA’s Technical List No. 35 are able to provide rollcage certification, and we’re proud to now be included on that list.

In order to gain our approval, we were required to construct a full size rollcage and carrying out destructive testing to confirm the accuracy of our computer modelling and demonstrate competency to the FIA. The testing and approval process has been a long one, and we’d like to thank the following people for their support throughout:

- Scott McGrath from CAMS for guiding us through the application process
- Rod, Siva and the team at Melbourne Testing Services for conducting the physical testing of the rollcage and materials
- Andy Nichols at Trackart for construction of the rollcage used in our physical tests
- Ross and the guys at Rob Black Engineering for construction of the test jigs and fixtures for the physical tests

An outline of the testing we performed and our FEA results is shown below. Have a look through and then help us spread the word by forwarding this email on to anyone else you think may find it of interest using the link at the bottom of the page. 

And if you would like to discuss a motorsport rollcage design or certification with us, please drop us a line or give us a call... we'd love to hear from you. 

Cheers, Brett.

Brett Longhurst
Managing Director

FIA Rollcage Test

Vertical Main Hoop

In order to demonstrate competence to the FIA, we were required to perform a physical test on a full size rollcage as per the FIA rollcage regulations, and then replicate the test using FEA. 

We designed a mild steel rollcage to suit the test rig, which was loosely based around a medium sized vehicle weighing approximately 1200kg.

The required load on the main roll hoop is dependent on the weight of the vehicle, and in this case was around 100kN or 10T. Once we'd run the FIA load, we also ran another test on the main hoop where we applied the maximum allowable displacement of 50mm, which required a load well over 20T. 

The rollcage was instrumented with multiple sensors and strain gauges so we could measure deflection and strain at various locations on the structure, and the load applied by the hydraulic cylinder was also recorded. 

Results from the physical test are compared with the FEA results below, and as you can see, the correlation was very good.

Additional Testing

High Displacement Roof Test

In order to take full advantage of the opportunity for testing and gain as much understanding as possible, we performed an additional test on the full cage to see what happens at very high levels of displacement. We moved the stamp forward onto the unsupported roof section and loaded it to the travel limit of the test machine at around 120mm.

This level of loading and deflection is highly non linear and modelling this behaviour using FEA is quite complex, so we were looking to study and correlate our models as much as possible. 
Again, the FEA results compared exceptionally well to the physical test:

Joint Tests

Detail T Piece Testing

Another set of additional tests we did was to understand behaviour around welded joints. For these tests, we designed a set of fixtures to test a T piece, which can also be used for testing bolted rollcage joints to the FIA standards. 
We tested various sizes of mild steel and chromoly T pieces and then fine tuned our FEA models of the welded regions to get good correlation. This was an invaluable part of the test schedule which gave us some critical insights into how to model failure of these welded joints both accurately and conservatively. 
As you can see, there's been a lot of time and effort invested into developing and validating our rollcage modelling methods. This investment has given us a high degree of confidence in our simulations and will help us provide you with a rollcage design that achieves the ultimate balance between safety and performance. 

If you would like to know more about our rollcage design and certification services, 
just drop us an email or give our office a call on +61 3 9029 3323 to have a chat to one of our engineers about what's possible. 
Copyright © 2015 Bremar Automotion, All rights reserved.

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