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ABSTRACT
In todays modern world, safety to driver and passengers is a major concern to every car manufacturer.
For accomplishing this, new standards are being set for the safety of the occupant in different car scenarios like frontal
head collision, side impact, rear impact and rollover. The automotive chassis is the main load carrier and energy absorbing
component in all crash events. In the modern world, fuel consumption also constituted as a serious issue that has to be
considered. Keeping all these constrains in consideration, a light and strong material should be used in chassis. In current
work, chassis has been designed using computer aided design (CAD) programme Solid Works and was analyzed using a
finite element analysis (FEA) programme ANSYS. The current research provides a standard finite element analysis
procedure for designing off road vehicle chassis. A multi body dynamic crash analysis is an option to understand the exact
behavior of the chassis for frontal and rear head collisions, to study the effect of speed of a vehicle. This report includes the
creation of the safe design for dynamic impact analysis under different loading conditions (different pipe size and
velocity).
FEA
FEA is a great computational tool in engineering field which is used to accomplish various engineering analysis.
In FEA the whole surface is divided into small confined area i.e. mesh generation which divides the whole complex
problem into small elements which is performed on simulating software which works on the different codes. Finite element
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analysis (FEA) calculates how a product reacts to forces, vibration, heat, fluid flow, and other physical effects. FEA works
by breaking down an object into a large number of finite elements after that mathematical equations helps to predict the
behavior of each element [2].
ANSYS
ANSYS is great simulating software which has the environment for solving the non-linear analysis and has the
very easy set up for the complex problems, even multi-physical simulations are possible. ANSYS can import CAD data
and also has features to build geometry with in itself. ANSYS Workbench is a platform which integrate simulation
technologies and parametric CAD systems. ANSYS can carry out advanced engineering analyses quickly and practically
by its variety of contact algorithms, time based loading features and nonlinear material models [3].
SOLID WORKS
Solid Works is a 3D solid modelling software package developed by the French company Dassault Systems, used
to develop various concepts designs based on parametric technology. It is used extensively to develop conceptual 3D solid
models of off road vehicles and final optimized model and is able to convert cad data to IGS and STL file formats, so that
can be assessed by analysis software package and rapid prototyping machine.
METHODOLOGY
Figure 1
The purpose of this section is to give a basic knowledge of the methodology that was used to analyze the Chassis.
The flow chart shows a generic illustration of the major steps involved in the design optimization process.
Material
1
2
AISI 1010
Concrete
Young
Modulus
(GPA)
200
140
Tensile
Strength
(MPA)
325
Yield
Strength
(MPA)
180
5
Poisson
Ration
0.30
0.21
Density X
1000
(Kg/M3)
7.872
2.4
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Design Optimization and Statistical Crash Analysis of Chassis Frame for Off Road Vehicle
After defining the material properties, the loading conditions need to be defined. In Explicit dynamics different
velocities were given to the chassis and deformations were measured with respect to given velocities while hitting the wall.
The analysis time 5 e -3 sec was given to chassis.
Table 2: Different Velocities Given to Chassis Frame
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Design Optimization and Statistical Crash Analysis of Chassis Frame for Off Road Vehicle
Figure 10: Maximum Displacement in Frame at Velocity 25 M/S for Back Impact
CONCLUSIONS
The basic objective of the present research was to optimize the design of the off road vehicle frame by reducing
the thickness of circular pipe. Deformations observed by reducing the thickness of the frame shows that if we use the pipe
with thickness of 1mm the deformations are quite similar as compared to design of the off road vehicle which is taken into
consideration in this research. According to the considered design, thickness of the frame should be 1.67 mm but if we
reduced it to 1 mm, percentage deformation observed in the chassis frame is only 2 % and moreover the weight of the
chassis reduces to 21 kg. Which shows that the frame is light weight and vehicle can generate more torque and power.
REFERENCES
1.
Charles M. Farmer, Elisa R. Braver and Eric L. Mitter, Two vehicle side impact crashes: The relationship of
vehicle and crash characteristics to injury severity, A & d. Anal. and Prev, Vol. 29, No. 3, pp. 399-406, 1997.
2.
Kim, S. S, Shabana, A. A, and. Haug, E. J, Vehicle Dynamic Analysis with Flexible Components, Iowa State
University, 1984.
3.
V. Veloso , H. S. Magallanes, G. I. Bicalho , E.S. Palma, Failure investigation and stress analysis of a longitudinal
stringer of an automobile chassis, Engineering Failure Analysis vol. 16, 2009, pp.16961702.
4.
Norma F. Hubele and Mark W. Arndt, A review of crash data analysis in a defect and recall investigation of the
general motor c/k pickup trucks, Accid. Anal. And Pm, Vol. 28, No. 1, pp. 33-42
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