ISSN 2395-1621 Application of Finite Element Analysis …ierjournal.org/vol1iss11/64Application of Finite Element...Parametric Optimization of Eicher 11.10 Chassis Frame for Weight

www.ierjournal.org International Engineering Research Journal (IERJ) Volume 1 Issue 11 Page 1628-1637, 2016, ISSN 2395-1621

© 2015, IERJ All Rights Reserved Page 1

ISSN 2395-1621

Application of Finite Element Analysis

on Heavy Duty Vehicle (Generic)

Chassis

#1Vaibhav Sapkal,

#2Dr.N.K.Nath

1 [email protected]

[email protected]

#1

JSPM’s Narhe Technical Campus (NTC) -Rajarshi Shahu School of Engineering & Research Narhe Pune M.E Mechanical Design Second Year

#2

Rajarshi Shahu College of Engineering Tathawade Pune 411033

ABSTRACT

ARTICLE INFO

The main Purpose of this project is to suggest the best suited material for the Generic

Chassis frame from von mises stresses and deflection point of view, along with modal

analysis and also to provide a base for weight reduction of the chassis frame. For this

generic Bus with High-Floor is selected. 3D model of bus chassis is done by using Cero

2.0 ( CAD Software) with the help of reverse engineering method , research paper and

Automobile engineers .Static and Modal analysis is done by using ANSYS 15.0 (FEA

Software), with three different types of materials and two load conditions. A

comparative analysis is done on different materials.

Article History

Received :12th

January 2016

Received in revised form :

13th

January 2016

Accepted :17th

January , 2016

Published online :

19th January 2016

I. INTRODUCTION

SCOPE AND OBJECTIVES:

To Design Generic Bus Chassis Model using CAD

Software.

To Obtain Structural and Modal Analysis using

FEA Software.

To validate the result of FEA model on three

different types of materials.

II. FLOW CHART

Fig 1. Flow Chart for Generic Bus Chassis Analysis

III. VEHICLE SPECIFICATION

3.1 Defining Vehicle Specification:

mailto:[email protected]

mailto:[email protected]



An intercity bus (TypeIII High Floor

Level, 24X16) is selected.

Design of Bus chassis is as per (ARAI)

AIS-052 standard.

The parts selection and their position are

also as per standard.

Modification is according to safe design

of given Generic chassis.

3.2 Seating Layout of Generic Bus

Fig 2. Seating Layout 45+1

3.3 Vehicle Dimensions -

Wheel Base –

5495mm

Overall Length – 11000

mm

Overall Width –

2550 mm

Overall Height – 3570

mm

Rear Over Hang – 4390

mm

Front Overhang – 1115

mm

Floor Height –

1240mm

Length of chassis –

10500mm.

C type side cross Channel –

230x75x8mm, 2nos/bus

Distance between two side bar –

840mm

Material of the chassis – ST52.

Cross members –

8nos/bus

Cross member mtg bracket c type –

230x200x145 &4mm thick.

3.4 Weight Distribution

Table 1. Weight Distribution

IV. MODELLING

3D model of above Generic Bus Chassis is done using CAD

software. The dimensions of the chassis are taken from

Reverse Engineering Method, Research Papers and

Automobile Engineers.

Fig 3. Chassis Cad Model in Creo2.0 (CADSoftware)

V. MATERIAL SELECTION

Material ST52 Aluminum Alloy(A356)

Steel46

Modulus of

Elasticity

2 x105

N/mm2

68.9 N/mm2 193

N/mm2

Poisson ratio 0.3 0.33 0.25

Tensile Strength 520 N/mm2 310 N/mm2 415

N/mm2

Yield Strength 360 N/mm2 276 N/mm2 297

N/mm2

(Table 2. Material used for Analysis)



VI. PREPROCESSING

6.1Mesh

Figure 4. Meshing of Chassis in Ansys 15.0 (FEA Software)

Nodes: 229628 Elements: 111815

6.2 Loading condition:

Load condition: - load is applied in the form of pressure on

the upper surface of side bars.

Load 1 (12 ton)

Pressure= Load/ Area

= 58860/787500

=0.0747 MPa

The above pressure is applied on both the side bars

Load 2 (16 ton)

6 ton on Both side of Given Chassis

Pressure= Load/ Area

= 75993/787500

=0.0965 MPa

The above pressure is applied on both the side bars

8 ton on Both side of Given Chassis

6.3 Fixed Support (Boundary conditions)

There are 4 boundary conditions of model; the first two

boundary conditions are applied in front of the chassis, the

other 2 boundary conditions are applied in rear of chassis,

there are shown in Figure. These points on the regions of

where leaf springs are fixed on the axle.

Fig 5. Pressure & Fixed Conditions

VII. POST PROCESSING

7.1 Equivalent Stress

Fig 6. ST 52 Equivalent Stress Load 1



Fig 7. ST 52 Equivalent Stress Load 2

Fig 8. A356 Equivalent Stress Load 1

Fig 9. A356 Equivalent Stress Load 2

Fig 10. Steel 46 Equivalent Stress Load 1

Fig 11. Steel 46 Equivalent Stress Load 2

7.2 Total Deformation

Fig 12. ST 52 Deformation Load 1& Load 2



(Fig 13. A356 Deformation Load1 &Load 2)

(Fig 14. Steel 46 Deformation Load 1 & Load 2)

7.3 Modal Analysis

(Fig 15. ST 52 Mode Shape 1 &2 )



(Fig 16. ST 52 Mode Shape 3 & 4)

(Fig 17. ST 52 Mode Shape 5 & 6)



Fig 18. A356 Mode Shape 1 & 2





Fig 21. Steel 46 Mode Shape 1& 2



Fig 22. Steel 46 Mode Shape 3 & 4

Fig 23. Steel 46 Mode Shape 5 & 6

VIII. RESULT

(Table No.3 Result for Load 1 & 2)

IX.CONCLUSION

From the above results the optimum material use for the

Generic chassis is Steel 52. Even though the Von misses

stress for Steel 52 is greater than Aluminum alloy, but the

deflection for steel 52 which is lowest among three

materials.

REFRENCES

[1] Tushar M. Patel, Dr. M. G. Bhatt ,Harshad K. Patel “

Parametric Optimization of Eicher 11.10 Chassis Frame for

Weight Reduction Using FEA-DOE Hybrid Modeling” Iosr

Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 6, Issue 2

(Mar. - Apr. 2013), PP 92-100

Load 1 Load 2

Sr.

No.

Material Von Misses Stress

MPa

Deflection

mm

Von Misses Stress

MPa

Deflection

mm

1 Steel 52 175.94 7.91 234.7 10.55

2 Aluminum Alloy 174.66 22.98 232.99 30.65

3 Steel 46 177.99 8.18 237.94 10.92



[2] Tushar M. Patel, Dr. M. G. Bhatt, Harshad K. Patel

“Analysis and validation of Eicher 11.10 chassis frame

using Ansys” International Journal of Emerging Trends &

Technology in Computer Science (IJETTCS)ISSN2278-

6856, Volume 2, Issue 2, March-April 2013.

[3] Swami K.I, Prof. Tuljapure S.B. “ Analysis of Ladder

Chassis of Eicher 20.16 Using FEM” IOSR Journal of

Applied Geology and Geophysics (IOSR-JAGG) e-ISSN:

2321–0990, p-ISSN: 2321–0982.Volume 2, Issue 1 Ver. I.

(Jan. 2014), PP 06-13

[4] Salvi Gauri Sanjay, Kulkarni Abhijeet 2, Gandhi Pratik

Pradeep, Baskar P. “Finite Element Analysis of Fire Truck

Chassis for Steel and Carbon Fiber Materials” Salvi Gauri

Sanjay et al Int. Journal of Engineering Research and

Applications ISSN : 2248-9622, Vol. 4, Issue 7 ( Version 2),

July 2014, pp.69-74

[5] Sairam Kotari ,V.Gopinath “Static And Dynamic

Analysis On Tatra Chassis” International Journal of Modern

Engineering Research (IJMER) Vol.2, Issue.1, pp-086-094

ISSN: 2249-6645

[6] AIS-052(Rev.1) standard . (www.araiindia.com).

http://www.araiindia.com/

Documents

ISSN 2395-1621 Application of Finite Element Analysis …ierjournal.org/vol1iss11/64Application of Finite Element...Parametric Optimization of Eicher 11.10 Chassis Frame for Weight