International Journal of Mechanical and

Production Engineering Research and

Development (IJMPERD)
ISSN 2249-6890
Vol. 3, Issue 4, Oct 2013, 99-106
TJPRC Pvt. Ltd.

REDUCING EFFECT OF BENDING LOAD AND TORQUE LOAD ON A HEAVY VEHICLE

FRONT AXLE USING COMPOSITES
RAJASEKHAR J1, SAMA BHARGAV2 & SAGINA DOONDI NAGARJUNA3
1

Associate Professor, Department of Mechanical Engineering, PEC, Andhra Pradesh, India

2,3

UG Student, Department of Mechanical Engineering, PEC, Andhra Pradesh, India

ABSTRACT
An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle may be fixed to the wheels,
rotating with them, or fixed to its surroundings, with the wheels rotating around the axle. Conventionally the front axle is a
dead axle. In such a case, the front axle beam is usually a drop forging of steel. This type of axle is no more used in modern
cars, although it is still being used in heavier vehicles. The steels used for this are 0.4% carbon steel or 1.3% nickel steel.
The axle has to take bending loads due to weight of the vehicle and also torque loads due to braking of the wheels. For this
reason, front axle is made of I section in the central portion, while the ends are made either circular or elliptical.
A downward sweep is given to the center portion to keep a low chassis height. In our project, a basic model of front axle is
prepared. The optimization of front axle is done by varying materials and its cross section. The present used material used
steel. Steel is replaced with Composite materials E-Glass Epoxy and S 2 Glass epoxy to reduce the weight of the axle.
By reducing the weight, steering becomes easier. Pro/Engineer is used for modeling and ANSYS is used for analysis.

KEYWORDS: Rigid Axle, Composite Materials, CADD, Pro-E, ANSYS9.0, Motor Vehicles
INTRODUCTION
Front Axle: Conventionally the front axle is a dead axle. In such a case, the front axle beam is usually a drop
forging of steel. This type of axle is no more used in modern cars, although it is still being used in heavier vehicles.
The steels used for this are 0.4% carbon steel or 1.3% nickel steel. The axle has to take bending loads due to weight of the
vehicle and also torque loads due to braking of the wheels. For this reason, front axle is made of I section in the central
portion, while the ends are made either circular or elliptical. A downward sweep is given to the center portion to keep a
low chassis height.
Composites: The concept of composites was not invented by human beings; it is found in nature. An example is
wood, which is a composite of cellulose fibers in a matrix of natural glue called lignin. The shell of invertebrates, such as
snails and oysters, is an example of a composite. Such shells are stronger and tougher than man-made advanced
composites. Scientists have found that the fibers taken from a spiders web are stronger than synthetic fibers.
CAD also known as Computer Aided Design, is the use of computer technology for the process of design and
design-documentation. Computer Aided Drafting describes the process of drafting with a computer. CAD software, or
environments, provide the user with input-tools for the purpose of streamlining design processes; drafting, documentation,
and manufacturing processes. CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of physical
components, but it is also used throughout the engineering process from conceptual design and layout of products, through
strength and dynamic analysis of assemblies to definition of manufacturing methods of components. It can also be used to
design objects.

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Rajasekhar J, Sama Bhargav & Sagina Doondi Nagarjuna

PRO/ENGINEER WILDFIRE
Pro/ENGINEER Wildfire is the standard in 3D product design, featuring industry-leading productivity tools that
promote best practices in design while ensuring compliance with your industry and company standards. Integrated
Pro/ENGINEER CAD/CAM/CAE solutions allow you to design faster than ever, while maximizing innovation and quality
to ultimately create exceptional products.
The main modules are Part Design, Assembly, Drawing and Sheet Metal
PRESENT MODEL OF FRONT AXLE

Figure 1: Step 1

Figure 2: Step 2

Figure 3: Step 3

Figure 4: Step 4

Figure 5: Step 5

Figure 6: Step 6

Reducing Effect of Bending Load and Torque Load on a Heavy Vehicle Front Axle Using Composites

Figure 7: Step 7

101

Figure 8: Step 8

ABOUT FEA
Finite element analysis (FEA) was first developed in 1943 by r. Courant, who utilized the ritz method of
numerical analysis and minimization of variational calculus to obtain approximate solutions to vibration systems. Shortly
thereafter, a paper published in 1956 by m. J. Turner, r. W. Clough, h. C. Martin, and l. J. Top established a broader
definition of numerical analysis. The paper centered on the "stiffness and deflection of complex structures".
By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics,
automotive, defense, and nuclear industries. Since the rapid decline in the cost of computers and the phenomenal increase
in computing power, FEA has been developed to an incredible precision. Present day supercomputers are now able to
produce accurate results for all kinds of parameters.
FEA consists of a computer model of a material or design that is stressed and analyzed for specific results. It is
used in new product design, and existing product refinement. A company is able to verify a proposed design will be able to
perform to the client's specifications prior to manufacturing or construction. Modifying an existing product or structure is
utilized to qualify the product or structure for a new service condition.in case of structural failure, FEA may be used to help
determine the design modifications to meet the new condition.
There are generally two types of analysis that are used in industry: 2-D modeling, and 3-D modeling. While 2-D
modeling conserves simplicity and allows the analysis to be run on a relatively normal computer, it tends to yield less
accurate results. 3-D modeling, however, produces more accurate results while sacrificing the ability to run on all but the
fastest computers effectively. Within each of these modeling schemes, the programmer can insert numerous algorithms
(functions) which may make the system behave linearly or non-linearly. Linear systems are far less complex and generally
do not take into account plastic deformation. Non-linear systems do account for plastic deformation, and many also are
capable of testing a material all the way to fracture.
FEA uses a complex system of points called nodes which make a grid called a mesh. This mesh is programmed to
contain the material and structural properties which define how the structure will react to certain loading conditions. Nodes
are assigned at a certain density throughout the material depending on the anticipated stress levels of a particular area.
Regions which will receive large amounts of stress usually have a higher node density than those which experience little or
no stress. points of interest may consist of: fracture point of previously tested material, fillets, corners, complex detail, and
high stress areas. The mesh acts like a spider web in that from each node, there extends a mesh element to each of the
adjacent nodes. This web of vectors is what carries the material properties to the object, creating many elements.
Ansys is general-purpose finite element analysis (FEA) software package. Finite element analysis is a numerical

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Rajasekhar J, Sama Bhargav & Sagina Doondi Nagarjuna

method of deconstructing a complex system into very small pieces (of user-designated size) called elements. The software
implements equations that govern the behaviour of these elements and solves them all; creating a comprehensive
explanation of how the system acts as a whole. These results then can be presented in tabulated, or graphical forms.
This type of analysis is typically used for the design and optimization of a system far too complex to analyze by hand.
Systems that may fit into this category are too complex due to their geometry, scale, or governing equations.
Ansys is the standard FEA teaching tool within the mechanical engineering department at many colleges. Ansys is
also used in civil and electrical engineering, as well as the physics and chemistry departments. Ansys provides a
cost-effective way to explore the performance of products or processes in a virtual environment. This type of product
development is termed virtual prototyping. With virtual prototyping techniques, users can iterate various scenarios to
optimize the product long before the manufacturing is started. This enables a reduction in the level of risk, and in the cost
of ineffective designs. The multifaceted nature of ansys also provides a means to ensure that users are able to see the effect
of a design on the whole behavior of the product, be it electromagnetic, thermal, mechanical etc.

STRUCTURAL AND MODAL ANALYSIS

Structural Analysis of Present Model: Material Steel
Element Type

Material Properties :

Solid 20 node 95
EX

= 200000N/mm

PRXY = 0.295
Density = 0.000007872 kg/mm
Loads

Pressure = 0.0769N/mm

Figure 9

Figure 10: Meshed Model in Ansys

Figure 11: Meshed Model with the Loads

Reducing Effect of Bending Load and Torque Load on a Heavy Vehicle Front Axle Using Composites

103

Solution
Solution Solve Current LS ok
Post Processor
General Post Processor Plot Results Contour Plot - Nodal Solution DOF Solution Displacement Vector
Sum

Figure 12: Displacement Vector Sum

General Post Processor Plot Results Contour Plot Nodal Solution Stress Von Mises Stress

Figure 13: Von Mises

Modal Analysis
Main menu>Preprocessor>Loads>Analysis Type>
New Analysis> Select Modal>Click> OK
Main menu>Preprocessor>Loads>Analysis Type>Analysis Options>
No. Of Modes to Extract: 5 Click> OK
Main menu>Solution>Solve>Current Ls>Ok

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Rajasekhar J, Sama Bhargav & Sagina Doondi Nagarjuna

RESULTS
Main menu>General Postproc>Read Results> First Set
Plot result>Deformed Shape>Def+ Undeform > Click> OK

Figure 14: Def+ Undeform

MATERIAL E-GLASS EPOXY EPOXY

Structural Analysis of Present Model
Solution
Solution Solve Current LS ok
Post Processor
General Post Processor Plot Results Contour Plot - Nodal Solution DOF
Solution Displacement Vector Sum
Element Type

Material Properties:

Solid 20 node 95
EX

= 50000N/mm

PRXY = 0.33
Density = 0.000002kg/mm

Figure 15: Displacement Vector Sum

Reducing Effect of Bending Load and Torque Load on a Heavy Vehicle Front Axle Using Composites

General Post Processor Plot Results Contour Plot Nodal Solutio n Stress Von Mises Stress

Figure 16: Von Mises Stress

Modal Analysis
Main menu>Preprocessor>Loads>Analysis Type>
New Analysis> Select Modal>Click> OK
Main menu>Preprocessor>Loads>Analysis Type>
Analysis Options>No. Of Modes to Extract: 5 Click> OK
Main menu>Solution>Solve>Current Ls>Ok

RESULTS
Main menu>General Postproc>Read Results> First Set
Plot result>Deformed Shape>Def+ Undeform > Click> OK

Figure 17: Def+ Undeform

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Rajasekhar J, Sama Bhargav & Sagina Doondi Nagarjuna

RESULTS
Structural Analysis Results
Table 1: Present Model of Rigid Axle
Material
Steel
E Glass Epoxy

Displacement (mm)
0.126539
0.051682

Von Mises Stress (n/mm2)

17.257
16.998

Permissible Stress (n/mm2)

620
1000

Modal Analysis Results

Table 2: Present Model of Rigid Axle
Modes
MODE 1
MODE 2
MODE 3
MODE 4
MODE 5

Steel
HZ
mm
3.105
0.12
3.521
0.11
5.165
0.11
9.609
0.11
11.02
0.22

E Glass Epoxy
HZ
Mm
9.528
0.24
11.2
0.216
19.12
0.209
29.55
0.216
33.72
0.445

CONCLUSIONS

In our project we have modeled a front axle used in heavy vehicles in the 3D modeling software Pro/Engineer.
The present model is of I section and we have modeled another front axle. The weight of the actual model is
about 214kgs and that of modified model is about 181kgs. The weight of the front axle is reduced almost by
30kgs.

Present used material for front axle is steel. We are replacing with E-Glass Epoxy. The density of E-Glass Epoxy
is less than that of Steel. Thereby the weight of the front axle reduces when E-Glass Epoxy.

We have done structural analysis and modal analysis for model using Steel, E-Glass Epoxy to verify the strength
and determine the frequencies.

By observing the analysis results, the stress values obtained are less than their permissible stress values for the
two materials. So, E-Glass Epox is safe for front axle. The stress values are also within the limit.

By considering weight and analysis results, we conclude that S2 Glass Epoxy is better.

REFERENCES
1.

Manufacturing of parts using composites from wikipedia

2.

Mechanics of composite materials by authar. K. Kaw

3.

Mechanics of laminated composite plates and shells- j. N. Reddy

4.

Engineering mechanics of composite materials- issac m . Daniel

5.

A text book of automobile engineering by r.k. Rajput, lp publications

6.

Fundamentals of motor vehicle technology by v.a.w. Hillier,