“Modelling and Analysis of Heavy Vehicle Chassis
Frame Made by Using Carbon Fiber and Composite
Material: A Comparative Study.”
Er. Bhimsen Shrestha
Mechanical Engineer,
KL College of Engineering, Green Fields, Vaddeswaram, Guntur District, India
ABSTRACT Automotive chassis is the
important component of automobile that
works as a frame work for holding all the
important part of vehicle like Engine,
Steering Systems, Suspension System etc. It
should be hence stiff and rigid to withstand
the shock, twist, vibration and strength. The
conventional chassis is very heavy and
bulky in nature due to that it contributes in
higher emission and less efficiency of
vehicle.
In this paper firstly, the chassis frame
of Eicher truck 11.0 is modeled in Pro-E
Creo Parametric 3.0 software and the
further analysis is done in ANSYS 17.2 by
using the composite material like carbon
fiber, S- Glass Epoxy and E-Glass Epoxy.
To study the vibration characteristics
of the chassis frame and to know the natural
frequency of the chassis frame, Modal
Analysis is done. Furthermore, Harmonic
analysis is done to know the von misses
stress in the chassis frame at that natural
frequency which incurs maximum
deformation in chassis frame. Finally, the
results are compared to know which is
suitable material for the chassis frame.
Keywords: Chassis Frame, Composite
Material, Modal Analysis, Harmonic
Analysis, Strength Comparison.
INTRODUCTION:
Chassis is a French term and was
initially used to denote the frame parts or
Basic Structure of the vehicle. It is the back
bone of the vehicle. A vehicle without body
is called Chassis. It consists of an internal
framework that supports a manmade object
in its construction and use. It is analogous to
an animal's skeleton. An example of a
chassis is the under part of a motor vehicle,
consisting of the frame (on which the body
is mounted).
The components of the vehicle like
Power plant, Transmission System, Axles,
Wheels and Tires, Suspension, Controlling
Systems like Braking, steering etc., and also
electrical system parts are mounted on the
Chassis frame. It is the main mounting for
all the components including the body. So, it
is also called as Carrying Unit.
The following main components of the
Chassis are
1. Frame: it is made up of long two
members called side members riveted
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 together with the help of number of
cross members.
2. Engine or Power plant: It provides
the source of power.
3. Clutch: It connects and disconnects
the power from the engine fly wheel
to the transmission system,
4. Gear box.
The frame is the main part of the
chassis on which remaining parts of
chassis are mounted. The frame should
be extremely rigid and strong so that it
can withstand shocks, twists, stresses and
vibrations to which it is subjected while
vehicle is moving on road. It is also
called underbody. The frame is supported
on the wheels and tire assemblies. The
frame is narrow in the front for providing
short turning radius to front wheels. It
widens out at the rear side to provide
larger space in the body.
LITERATURE REVIEW
Automotive chassis is a skeletal
structure on which various other mechanical
parts are assembled. In late 1900s, the
chassis existed in wooden frame with the
metal panel arrangement, then wooden
frame reinforced with steel was introduced
to give the chassis a greater rigidity. Finally,
steel ladder frames became common in 1930
with composite material structures. The
chassis is the most crucial element and
significant component which are basically
made from steel. Chassis Frame must be
stiff enough to withstand all the forces and
loads acting on it statically and dynamically
and forces like shock, twist and vibration.
The chassis provides the strength needed for
supporting the different vehicular
components as well as the payload and helps
to keep the automobile rigid and stiff.
Consequently, the chassis is also an
important component of the overall safety
system. Furthermore, it ensures low levels of
noise, vibrations and harshness throughout
the automobile. Along the strength, an
important consideration is chassis design is
to have adequate bending and torsional
stiffness for better handling characteristics.
So, strength and stiffness are two important
criteria for the design of chassis. The load
carrying structure is the chassis, so the
chassis has to be so designed that it has to
withstand the loads that are coming over it.
Composite material like carbon fiber
S-glass and E-glass Epoxy fiber recently
gained a wide acceptance in the automobile
industry due to their light weight and high
strength as compare to conventional
automobile frame which is manufactured
from steel and its alloy. Increasing demand
of highly efficient and less weight
automobile’s have made the researcher to do
brain storming to search new materials and
composite materials gained wide attention to
be introduced in auto vehicle due to their
less dense and high strength and stiff in
nature. Finite element analysis is most
widely used analysis technique due to its
ease of use and good comparable results. By
providing suitable boundary conditions on
can do the analysis like static, modal and
harmonic analysis. In this paper, Modal
analysis is done to determine the natural
vibrating frequency and maximum
deformation of the chassis frame by using
stainless steel, carbon fiber, S-glass Epoxy
Fiber and E-glass Epoxy Fiber. After that
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Harmonic analysis of chassis frame is done
by taking the natural frequency at which
maximum deformation is occurs at chassis
frame as input and corresponding von
misses stress is extract. On the basis of 17.Deflection of Chassis: - = 2.85 mm
modal analysis and harmonic analysis a
comparison is done of all the material’s
which is been used in this comparative
study.
That is within safe limit according
DETAILS OF CHASSIS FRAME deflect ion span ratio.
Model- EICHER 11.10
1. Side bar cross
section=210mm×76mm×6mm
2. Number of side bar= 2
3. Number of cross bar= 6
4. Channel = C- channel
5. Rear overhang= 1620mm
6. Front overhang= 935mm
7. Wheel base= 3800mm
8. Length of Chassis=6350mm
9. Width of Chassis=2150mm
10.Capacity of truck =8 ton
11.Weight of body and engine= 2 ton
12.Load Acting on Chassis Frame =8000
Kg = 78480N
Fig: -Cross Section of main
13.Engine and Body Weight = 2000Kg = frame
19620N
14.Over loaded Truck Capacity =
1.25%×78480=98100N
15.Total Load on Chassis Frame =
19620+98100=117720N
16.Load Acting on single frame = Total
load/2= 58860N

Now we can calculate the maximum

shear stress and maximum deflection
using equation given below
Fig: - Model- EICHER 11.10

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MATERIAL PROPERTIES possible to get the accurate results and at
some points the
Sl. No Properties Units Stainless Steel E-Glass Epoxy S-Glass Epoxy Carbon
Fiber Fiber Fiber

1. Density Kg/m3 7850 2500 2490 1600

2. Young’s Modulus GPa 200 72.5 85 155
3. Poison Ratio - 0.31 0.28 0.22 0.358
4. Tensile Strength GPa 3.2 3.45 4.6 4.1

CAD DESIGN OF CHASIS FRAME

Pro-E Creo Parametric 3.0 is used to
finer meshing is also done to get
model the chassis frame of Eicher11.0.3-D better results.
model of the chassis frame is shown in
Figure below.

Fig: - Meshing of Chassis Frame

Fig: - 3D Model of Chassis frame

MESHING OF CHASSIS FRAME

The finite element method (FEM) is a
numerical technique for finding approximate
solutions to boundary value problems FEM
subdivides a large problem into smaller,
simpler, parts, called finite elements
Meshing of chassis frame is done in Ansys
Workbench 17.2 and method used for
meshing is tetrahedrons surface mesher. The
size of elements is kept as minimum as
BOUNDARY CONDITIONS FOR
MODAL ANALYSIS
While doing software-based analysis,
it is necessary to apply boundary conditions.
In Modal analysis, the front two and last two
cross member are fixed there is no need to
apply loading conditions while doing modal
analysis ,natural frequencies of chassis
frame is outcome in modal analysis.
Boundary conditions for modal analysis is
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shown in figure.

Fig: -Boundary conditions for Modal Analysis

MODAL ANALYSIS:
Modal analysis is used to judge the
behavior of a body under vibrational Carbon Fiber
conditions and corresponding natural
frequency is determine. Dynamic analysis
can predict these variables with respect to
time/frequency. To determine natural
frequency of component, it is basic design
property. Natural frequency information is
also helpful for avoiding resonance,
reducing noise. In this paper, the intention of
doing the modal analysis is to determine the
natural frequency of chassis frame at which
maximum deformation occurs so that this
maximum natural frequency is used as input
in harmonic analysis to determine the
corresponding stress acting on chassis of
different material. E-Glass Epoxy Fiber

Stainless Steel

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 29.532 1.5873
Stainless 32.254 1.9937
Steel 44.488 2.3171
58.221 2.46
59.786 2.6386
Carbon 46.411 3.7637
Fiber 91.362 3.5175
99.365 4.4146
137.13 5.1319
180.06 5.4527
183.82 5.8466
E-Glass 15.662 2.9713
Epoxy Fiber 30.996 2.7681
S-Glass Epoxy Fiber
33.893 3.4787
46.737 4.0422
61.111 4.2886
62.875 4.6011
S-Glass 17.208 3.0275
Epoxy Fiber 34.127 2.86165
37.43 3.5435
51.564 4.1157
67.283 4.3601
69.345 4.3831

The results obtained from Modal

As clearly mentioned, the natural
frequencies of the Stainless Steel, Carbon
fiber, S-Glass Epoxy Fiber and E-Glass
Epoxy fiber are obtained from modal
analysis. These frequencies are taken as
input for harmonic analysis. The below table
shows the 6 modes shape’s frequency along
with deformation in the corresponding mode
shape frequency
Type Frequency Deformation
(Hz) (mm)
14.937 1.7022
analysis shows that since composite
materials being light in weight, it can vibrate
at maximum modal or natural frequency
than steel materials and hence it can be
deformed to high range without failure than
steel materials.
BOUNDARY CONDITIONS FOR
HARMONIC ANALYSIS:
In Harmonic analysis, front two, last
two cross member is fixed and also loading
condition is applied while doing analysis.
Most importantly natural frequency obtained
from modal analysis is taken as input while

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doing analysis so that at particular frequency
particular stress can be noted.

Carbon Fiber
Fig: -Boundary conditions for Harmonic Analysis

HARMONIC ANALYSIS:
Result obtained from Harmonic
analysis is used to verify the Steady State
response of a linear structure, enabling
researches, engineers and chassis designer to
determine whether in which the chassis can
withstand resonance, fatigue or other
structural problems related to vibration
during its operating life. Here in this paper
the natural frequency which has highest
deformation are uses as input and
corresponding stress induced is taken as
output which is used to compare that which
material has highest and lowest von misses
stress induced.

Stainless Steel E-Glass Epoxy Fiber

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 chassis frame. It means that composite
materials can bear the more stress than that
of steel. And also, the density of the
composite material is very less which helps
to drop down the weight of chassis frame
and assist in increasing the efficiency of the
automobile.

Natural Deformat Stress

S-Glass Epoxy Fiber Materials Frequency on (MPa)
(Hz) (mm) Harmonic
Analysis

Stainless 58.221 2.46 256.06

Steel
59.786 2.6386 59.786

Carbon 180.06 5.4527 3185.4

Fiber
183.82 5.8466 1251.1

E-Glass 61.111 4.2886 25618

Epoxy
62.875 4.6011 9333.3

S-Glass 67.283 4.3601 168740

Epoxy
69.345 4.3831 17663

From the result obtained, it can be

RESULTS AND DISCUSSION:
The results obtained from Modal
analysis shows that since composite
materials being light in weight, it can vibrate
at maximum modal or natural frequency
than steel materials and hence it can be
deformed to high range without failure than
steel materials.
From the harmonic analysis, it is
found that Composite materials shows more
von misses stress as compare to structural
steel at the natural frequency at which
maximum deformation occurs onto the
concluded that Composite material being
lighter in weight can vibrate at higher
natural frequency due to which it has the
high capacity to deform to higher range with
high stress without failure. Hence,
Composite materials could be the best
materials to be used for designing the
chassis.
Since, Composite material is very
costly as compare to other metal used in
auto vehicle chassis frame which incur some
extra cost on the consumer. When cost will
not be the factor the best alternative for the
automobile and chassis frame is composite
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materials. The results of the harmonic 8. AutarK. Kaw, "Mechanics of
analysis give a clear indication that the Composite Materials", CRC press,
composite materials can bear high stress 1997.
than that of steel materials without failure.

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