INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH …ijpret.com/publishedarticle/2014/7/IJPRET - 203.pdf · computer model or design that is stressed and analyzed for specific results

Research Article Impact Factor: 4.226 ISSN: 2319-507X Bhat KA, IJPRET, 2014; Volume 2 (12): 71-84 IJPRET

Available Online at www.ijpret.com

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INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH IN ENGINEERING AND

TECHNOLOGY A PATH FOR HORIZING YOUR INNOVATIVE WORK

FAILURE ANALYSIS AND OPTIMIZATION OF TRACTOR TROLLEY CHASSIS: AN

APPROACH USING FINITE ELEMENT ANALYSIS

BHAT KA1, UNTAWALE SP2, KATORE HV3

1. M Tech Student of CAD /CAM, Dept of Mechanical Engineering, D. M. I. E. T. R, Wardha,

India.

2. Principal, D. M. I. E. T. R, Wardha, India.

3. Assistant Professor, Dept of Mechanical Engineering, D. M. I. E. T. R, Wardha, India.

Accepted Date: 29/07/2014; Published Date: 01/08/2014

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Abstract: This paper aims to redesign a modified chassis for tractor trolley. The existing

trolley chassis designed by industry uses ‘C’ Cross section having dimension 200mm x

75mm x 7mm and the material used is mild steel. By keeping the material and dimension

similar and using ‘I’ cross section area instead of ‘C’ resulted in more safer stresses than ‘C’

and 31.79kg reduction in weight. As raw material required is less, cost of chassis ultimately

reduces.

Keywords: Chassis design, Cad model, Stress Analysis, Optimisation.

Corresponding Author: MISS. KSHITIJA A. BHAT

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How to Cite This Article:

Bhat KA, Untawale SP, Katore HV; IJPRET, 2014; Volume 2 (12): 71-84

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INTRODUCTION

A Chassis is one of the key components of tractor trolley. It consists of an internal framework

that supports the container of tractor trolley in its construction and use. It is a dead vehicle

which is connected to tractor trolley to carry the load. It serves as a frame work for supporting

the body. It should be rigid enough to withstand the shock, twist, and other stresses & its

principle function is to carry the maximum load for static and dynamic condition safely. An

important consideration in chassis design is to have adequate bending stiffness along with

strength for better handling characteristics. The Chassis is used to support the container on

which the load is to be carried out.

1.1 Functions of Chassis

To carry load of the goods carried in the body.

To withstand the forces caused due to the sudden braking or acceleration.

To withstand the stresses caused due to the bad road condition.

(a)

(b)

Figure 1.1: - A chassis of 6 tonne 2 wheeler trolley



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Various components or products used in rural areas are mostly manufactured in small scale

industries such as farming machinery, thrashers, tractor trolleys etc. It has been observed that

these rural products are not properly designed. Tractor trolleys are manufactured in small to

moderate scale industries. Three dimensional finite element analyses of the chassis consist of a

computer model or design that is stressed and analyzed for specific results. A company that is

able to verify a proposed design will be able to perform to the clients specifications prior to

manufacturing or construction. The general purpose finite element analysis software ANSYS is

used for present study. The variation of bending stress and displacement values are predicted.

With the Indian market becoming global and advent of Multinationals in the market, a cut

throat competition has a rise between the Indian companies and the Multinational company,

thus to remain in the contest it has become necessary for the Indian industries to improve and

innovate their product. There are many chassis manufacturers in vidharbha region having good

Potential but poor productivity having a scope for improvement. Awachat industries Limited,

Wardha is one of the leading tractor trolley manufacturers in the region manufacturing 3000

trolley and above. Up to now they are manufacturing them without much economical and

technical consideration. One of the important areas where one can improve the product quality

while keeping the cost low is the design aspect. One can design the product in such a way that

its performance increases while the customer has to pay less as compared to the same product

of other companies.

1. SPECIFICATION OF 6 TONNE 2 WHEELER TRACTOR TROLLEY CHASSIS

The total capacity of the trolley is 60KN but the self weight of trolley and the other accessories

is 13 KN. So we consider the gross weight come over is 73 KN. The existing chassis consists of ‘C’

cross section having cross section area 200mm x 75mm x 7mm and the material used in

manufacturing is mild steel. The specification of tractor trolley is shown in table 1 which is

collected from industry itself. Considering uniformly distributed load on the chassis where Point

A is starting point of chassis, Point C is the contact Point from where the trolley box is to be

mounted, Point B is the centre Point of leaf spring and Point D is the end Point of the trolley.



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Table1:- Specification of 6 tonne 2 Wheeler Tractor Trolley Chassis

General 6 Ton 2-Wheeler Box Type Trolley

Overall

Dimensions

Overall length 3100mm

(trolley box)

4025mm

(chassis )

Overall width 1900mm

(trolley box)

Overall height 730mm

(trolley box)

1700mm above ground

Load

capacity

Payload capacity 60KN

Unloaded weight

(chassis trolley box)

13KN

Gross load weight 73KN

Table2:- Structural Properties of Mild Steel

Structural Properties

Young's Modulus 210M Pa

Poisson's Ratio 0.3

Density 7840 kg/m³

Thermal Expansion 1.2e-005 1/°C



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3. STRUCTURAL ANALYSIS OF CHASSIS

In the present study, market available tractor trolley Chassis is selected and its dimension is

noted. The Possible loads acting and the place of loads are noted. According to the dimensions,

tractor trolley Chassis is modeled using PRO E software. It is then imported to design modeler

software ANSYS.

Figure 3.1:- Cad Model of Chassis

Figure 3.2.:- Load diagram of chassis

Figure 3.3:- Reaction diagram of chassis



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3.1 Calculation for Reactions

The chassis having the support at Point A and B, so reactions comes at Point A and Σ Fy =0

RA + RB = 102.20 +101.47 + 49.64

RA + RB = 253.31KN…………… (1)

Taking Moment At Point A

RB x 2.79= (49.64 x 3.13)+(101.47 x 2.095)+(102.20 x 0.7)

RB = 157.529KN…………………. (2)

From eqn (1)

RA = 95.781KN………………..…(3)

3.2 Calculations for Shear Forces acting on chassis:

SF at point D = 0KN

SF at D-B = -49.67KN

SF at B = -49.64+157.529 = +107.889KN

SF at B-C= 107.884-101.47= +6.419 KN

SF at C = + 6.419KN

SF at C-A = 6.419-102.20 = -95.781 KN

SF at A= -95.781+95.781= 0KN

3.2 Calculations for bending moments:

B.M at point D = 0 KN/m

B.M at point B = (-49.64 x 0.340) =-16.87760 KN/m

B.M at point C = (-49.64 x1.73) + (157.524 x1.390) – (101.47 x 0.695) = 62.5590 KN/m

B.M at point A = (-49.64 x3.13) + (157.524 x 2.79) – (101.47 x 2.095) –(102.20 x 0.7) = 0 KN/m

BMAX =(95.781x 1.3121) –(95.7833x0.655) =62.936 KN/m



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4. ANALYSIS OF EXISTING ‘C’ CROSS SECTION CHASSIS USING ANSYS TOOL

The existing chassis geometry is generated in ANSYS workbench 11 by selecting toolbox where

various commands like draw, dimensioning, constraints, extrude, generate, rotate etc. are used.

Then mesh is generated on the model and after that load points are defined and load values are

given. Then the results are generated automatically for stresses and deformation in solution

phase. Figure shows the ANSYS results for Mesh Generated, Total Deformation, Equivalent (von

misses) Stress, Shear Stress, Normal Stress, Biaxiality Indication, Factor of Safety.

Figure 4.1:- Force Diagram

Figure 4.2: -Mesh Generated



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Figure 4.3: -Von–mises stress

Figure 4.4:- Total Deformation

Figure 4.5: -Shear Stress



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Figure 4.6: -Normal Stress

Figure 4.7 :- Biaxiality Indication

Figure 4.8 :- Factor of Safety



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5. ANALYSIS OF MODIFIED ‘I’ CROSS SECTION CHASSIS USING ANSYS TOOL

Figure 5.1:- Force Diagram

Figure 5.2: -Mesh Generated

Figure 5.3: -Von–mises stress



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Figure 5.4:- Total Deformation

Figure 5.5: -Shear Stress

Figure 5.6: -Normal Stress



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Figure 5.7:- Biaxiality Indication

Figure 5.8 :- Factor of Safety

Table 3:- Comparision Between Existing Chassis And Proposed Chassis Using ANSYS

SR

NO.

FACTORS EXISTING ‘C’ SECTION SUGGESTED ‘I’ SECTION

1 Equivalent (Von-

Mises) Stress

75.452 MPa 34.648 MPa

2 Total Deformation 0.001877m 0.0002382 m

3 Shear Stress 20.875 MPa 7.5162 MPa

4 Normal Stress 40.409 MPa 13.088 MPa

5 Biaxiality Indication 0.98008 0.97657

6 Factor Of Safety 1.1424 to 5 2.4879 to 10

7 Mass 431.64 Kg 399.85 Kg



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CONCLUSION

The newly designed ‘I’ section Chassis reduces 31.79 Kg of weight as compared to the

existing ‘C’ section Chassis.

More safer stresses are obtained in new suggested design.

Increase in Factor of Safety obtained in new suggested design.

Reduction in weight shows that raw material required for manufacturing of the Chassis is

reduced.

As raw material required is reduced, reduction in cost is achieved.

ACKNOWLEDGEMENT

I express my deep sense of gratitude and Special thanks to Awchat Industries Pvt. Ltd., Wardha,

for giving me the required data.

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INTERNATIONAL JOURNAL OF PURE AND APPLIED RESEARCH …ijpret.com/publishedarticle/2014/7/IJPRET - 203.pdf · computer model or design that is stressed and analyzed for specific results