Development of a tipper body subframe - DiVA 785641/ ¢  Development of a tipper body subframe

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  • SchoolofInnovation,DesignandEngineering

    Development of a tipper

    body subframe -a pre-study at SSAB

    Master thesis work Advanced level,30 credits

    Product and process development

    Mattias Hägglund

    Report no: 2

    Commissioned by:SSAB

    Supervisor, SSAB: Hans Konradsson

    Supervisor, Mälardalen University:Bengt Erik Gustafsson

    Examiner:StenGrahn

    Fall Semester 2014

  • 2014 SSAB

    © Mattias Hägglund 2

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  • 2014 SSAB

    © Mattias Hägglund 3

    ABSTRACT

    This thesis is performed on master level and covers an assignment given by the Value Added Services(VAS) department at SSAB (Oxelösund, Sweden). The thesis has been carried out by Mattias Hägglundduring the fall of 2014 atMälardalen University. The transportation industry has over time developed to be more efficient and environmentally aware. Looking at the truck industry shows that the development is strong and constant, new solutions and improvements is being introduced every year. One result of this is reduced fuel consumption and/or increased loading capacity. In the mining industry for example, can a few hundred kilos extra payload make a big different at the end of the day. This constant development seen in many fields is something that SSAB wants to take part in. By using product diversification canthe VAS department reach new customers and secure sales of SSAB steel. Subframes, being a natural step from tipper bodies, are worth to consider as a possible project start-up. Combined with SSABs current tipper body program could a new subframe make its way to the market. This project have adapted a new product development process in order to come up with a subframe design not yet physically tested, but theoretically superior to conventional subframes. Each development phase of this process is explained and executed in the report, giving the reader a detailed step-by-step overview. The projects result builds on the knowledge attained from the course of the project and simulation results. With the use of a CAD-program and by applying FEM, have a number of concepts been analysed with regards to their strength and rigidity. The simulation results have made it possible to design a final solution where a number of demands and desired properties have been fulfilled. The result from this thesis work have reduced the weight by 7%, increased rigidity about 20% and substantially improved the strength in comparison to a typical subframe. This shows that there are possibilities to improve on the current subframe design, and that there is cause for SSAB to make further research and development in the subject of tipper body subframes. Keywords: SSAB, high strength steel, subframe, product development.

  • 2014 SSAB

    © Mattias Hägglund 4

    ACKNOWLEDGEMENTS

    The author would like to express his gratitude to SSAB in Oxelösund, for the opportunity to write this thesis with them. It has built confident and self-esteem to be trusted with this task. This assignment has been exciting and interesting from the start. Knowing very little while going in to the project and systematically building up information and knowledge have been an exciting journey. I would like to thank a number of people who have supported and helped me throughout this project. BengtGustavssonat MDH has been key to the success with which the project has concluded. His guidance and support through the simulations have secured the resultshigh quality. Hans Konradsson,Product Manager at SSAB hasshown strong belief in me and my judgement, being friendly and supportive on,as well as off work. A special thanks to Jonas Gozzi,Manager Market Development and R&D for taking time and lending his expertise to some of the more critical parts of the project. The author also wants to thank the persons and companies who took amoment to answer my questions and show me their production facilities. It gave valuable information later used in the development phase. Finally, thanks to everybody at SSAB who have supported my work and happily answered my questions. You have all made me feel welcome and as part of the group from day one. It has been greatly appreciated.

  • 2014 SSAB

    © Mattias Hägglund 5

    CONTENT 1 INTRODUCTION ........................................................................................................................................ 10

    1.1 SSAB ......................................................................................................................................................... 10 1.2 PROJECT BACKGROUND.............................................................................................................................. 10 1.3 PROBLEM FORMULATION ........................................................................................................................... 11 1.4 PROJECT AIM .............................................................................................................................................. 11 1.5 RESEARCH QUESTIONS ............................................................................................................................... 11 1.6 PROJECT LIMITATIONS................................................................................................................................ 12

    1.6.1 Time Frame ...................................................................................................................................... 12 1.6.2 Vehicles and Equipment ................................................................................................................... 12 1.6.3 Result ................................................................................................................................................ 12

    2 RESEARCH METHOD ............................................................................................................................... 13

    2.1 RESEARCH APPROACH ................................................................................................................................ 13 2.1.1 Qualitativeand Quantitative Data. ................................................................................................... 14 2.1.2 Primary and Secondary Data Gathering ......................................................................................... 14 2.1.3 Structured, Semi- and Unstructured Interviews ............................................................................... 15 2.1.4 Literature Review ............................................................................................................................. 15

    2.2 RESEARCH AND SOURCE CRITICISM ........................................................................................................... 16 2.2.1 Interviews ......................................................................................................................................... 16 2.2.2 Literature ......................................................................................................................................... 17

    3 THEORETIC FRAMEWORK ................................................................................................................... 18

    3.1 REFINED NEW PRODUCT DEVELOPMENT PROCESS ..................................................................................... 18 3.2 DEMAND SPECIFICATION ............................................................................................................................ 19 3.3 GANTT SCHEDULE ...................................................................................................................................... 19 3.4 HIGH STRENGTH STEEL .............................................................................................................................. 20

    3.4.1 Steel Improvements .......................................................................................................................... 20 3.5 SCANIA RULES AND DIRECTIVES ................................................................................................................ 21 3.6 CREATIVE TOOLS ....................................................................................................................................... 22 3.7 SIMULATED DRIVEN CONSTRUCTION ......................................................................................................... 22

    3.7.1 Finite ElementMethod ...................................................................................................................... 22

    4 EMPIRIC STUDY ........................................................................................................................................ 24

    4.1 DEFINE PROBLEM ....................................................................................................................................... 24 4.1.1 Demand Specification ...................................................................................................................... 25

    4.2 PROJECT PLANNING .................................................................................................................................... 25 4.3 RESEARCH .................................................................................................................................................. 25

    4.3.1 Literature and Document Review ............................................