DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS USING HONEY COMB STRUCTURE

68

International Journal of Research and Innovation (IJRI)


DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS USING HONEY COMB STRUCTURE

K.Rajesh 1, K.Durga2,

1 Research Scholar, Department Of Mechanical Engineering, Vikas college of Engineering and Technology,Vijayawada rural,A.P,India2 Assistant professor , Department Of Mechanical Engineering, Vikas college of Engineering and Technology,Vijayawada rural,A.PIndia

*Corresponding Author:

K.Rajesh , Research Scholar, Department Of Mechanical Engineering, Vikas college of Engineering and Technology,Vijayawada rural,A.P,India.

Published: December 22, 2014Review Type: peer reviewedVolume: I, Issue : IV

Citation: kaile.rajesh, Research Scholar (2014),Design And Analysis Of Heavy Vehicle Chassis Using Honey Comb Structure

Problem discripition

Chassis is one of the major part in vehicle construc-tion .Generally chassis is made of mild steel, these type of chassis models are due to heavy weight vehi-cle is giving less mileage and also cost of the chassis is high.

Rectification methodology

As we know that weight of the chassis is the ma-jor problem in manufacturing,cost and mileage as-pects.In this thesis composite materials (frp and crpf) will be analyzed for the replacement of traditional mate-rials structure.Composites are very low weight than mild steel and honey comb is one of the efficient composite for structure with very low weight and good structural stability.

INTRODUCTION TO CHASSIS

The chassis forms the main structure of the modern

automobile. A large number of designs in pressed-steel frame form a skeleton on which the engine, wheels, axle assemblies, transmission, steering mechanism, brakes, and suspension members are mounted. During the manufacturing process the body is flexibly bolted to the chassis.

This combination of the body and frame performs a variety of functions. It absorbs the reactions from the movements of the engine and axle, receives the reaction forces of the wheels in acceleration and braking, absorbs aerodynamic wind forces and road shocks through the suspension, and absorbs the major energy of impact in the event of an accident.

There has been a gradual shift in modern small car designs. There has been a trend toward com-bining the chassis frame and the body into a sin-gle structural element. In this grouping, the steel body shell is reinforced with braces that make it rigid enough to resist the forces that are applied to it. To achieve better noise-isolation characteristics, separate frames are used for other cars. The pres-ence of heavier-gauge steel components in modern separate frame designs also tends to limit intrusion in accidents.

INTRODUCTION OF CHASSIS FRAME:

Chassis is a French term and was initially used to denote the frame parts or Basic Structure of the ve-hicle. It is the back bone of the vehicle. A vehicle without body is called Chassis. The components of the vehicle like Power plant, Transmission Sys-tem, Axles, Wheels and tyre, Suspension, Control-ling Systems like Braking, Steering etc., and also electricalsystem parts are mounted on the Chassis

Abstract

Automotive chassis is a skeletal frame on which various mechanical parts like engine, tires, axle assemblies, brakes, steering etc. are bolted. The chassis is considered to be the most significant component of an automobile. It is the most crucial element that gives strength and stability to the vehicle under different conditions. This thesis deals with the design optimization and material suggestion for heavy vehicle chassis (container vehicle).In the first step literature survey will be conducted for further processes (for the selection of material and geometric selection).In the next step modeling will be done to carry out the analysis. Structural Analysis will be conducted using traditional material M.S; Composite materials FRP (E-glass)& Carbon epoxy (S-2 glass), also analysis will be conducted on present and updated models.In the next step impact test and fatigue analysis will be conducted on same to find impact and fatigue characteristics.Objective: By doing this project chassis manufacturing company can save time & efforts because of easy manufacturing method. End user can save money on chassis purchase and savings on reduced fuel consumption due to low weight of chassis with composites.

1401-1402

69


frame. It is the main mounting for all the compo-nents including the body. So it is also called as Car-rying Unit.

LAYOUT OF CHASSIS AND ITS MAIN COMPO-NENTS:

The following main components of the chassis are1. Frame: it is made up of long two members called side members riveted together with the help of num-ber of cross members.2. Engine or power plant: it provides the source of power3. Clutch: it connects and disconnects the power from the engine flywheel to the transmission sys-tem.4. Gear box5. U joint6. Propeller shaft7. Differential

Functions of the chassis frame:

1. To carry load of the passengers or goods carried in the body.2. To support the load of the body, engine, gear box etc.,3. To withstand the forces caused due to the sudden braking oracceleration4. To withstand the stresses caused due to the bad road condition.5. To withstand centrifugal force while corneringTypes of chassis frames:There are three types of frames1. Conventional frame2. Integral frame3. Semi-integral frame

WELDING IMPROVEMENTS

As most body shells are manufactured by spot weld-ing the panels together, a simple way to stiffen them up is to either stitch or seam weld them instead. As with welding during construction of a chassis, care must be taken to avoid problems due to excessive heat. Normally, additional welding is concentrated on specific areas, such as suspension mounting points or the engine bay, as it is quite a labor in-tensive technique. Most of the time, a full rollcage would be fitted instead of additional welding, but in some instances where a cage is not going to be used, full welding of the entire shell can take place.

INTRODUCTION TO CAD

Throughout the history of our industrial society, many inventions have been patented andWhole new technologies have evolved. Perhaps the single de-velopment that has impactedManufacturing more quickly and significantly than any previous technol-ogy is the digital computer.Computers are being used increasingly for both de-sign and detailing of engineering componentsin the drawing office.

Computer-aided design (CAD) is defined as the ap-plication of computers and graphicsSoftware to aid or enhance the product design from conceptualiza-tion to documentation.CADis most commonly as-sociated with the use of an interactive computer graphics system, referred toas a CAD system. Com-puter-aided design systems are powerful tools and in the mechanicaldesign and geometric modeling of products and components.There are several good reasons for using a CAD sys-tem to support the engineering design function:

• To increase the productivity• To improve the quality of the design• To uniform design standards• To create a manufacturing data base• To eliminate inaccuracies caused by hand-copying of drawings and inconsistency between• Drawings

MODEL OF EXISTING CHASSIS

The above image shows final model of existing chas-sis

MODEL OF MODIFIED CHASSIS

The above image shows final model of modified chassis

70


The above image shows detail of modified chassis

MODEL OF HONEY COMB CHASSIS

The above image shows final model of honey-comb chassis

The above image shows detail of honeycomb chassis

2D DRAWINGS OF MODELS

The above image shows 2d drafting of existing chas-sis

The above image shows 2d drafting of modified chassis

The above image shows 2d drafting of honeycomb chassis

INTRODUCTION TO 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 vibra-tion systems. By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nu-clear industries. Since the rapid decline in the cost of computers and the phenomenal increase in com-puting power, FEA has been developed to an incred-ible precision. Present day supercomputers are now able to produce accurate results for all kinds of pa-rameters.

STRUCTURAL ANALYSIS ON EXISTING DESIGN OF CHASSIS

MILD STEEL

The above image is the imported model of chassis. Modeling was done in Pro-E and imported with the help of IGES (Initial Graphical Exchanging Specifi-cation).

71


The above image showing the meshed modal. De-fault solid Brick element was used to mesh the com-ponents. The shown mesh method was called Tetra Hydra Mesh.Meshing is used to deconstruct complex problem into number of small problems based on finite ele-ment method

LOAD: 20 TONS

The above image shows the loads applied

RESULTSDisplacement

The above image shows displacement value 1.4895 mm

The above image shows von-misses stress value 12.426 N/mm2

The above image shows strain value 0.0000592FATIGUE ANALYSIS ON EXISTING DESIGN OF CHASSIS

The above image shows safety factor value 15

The above image shows Biaxiality indication value 0.91413

72


The above image shows alternating stress value 24.853


E glass epoxy



The above image shows strain value 0.00014155

FATIGUE ANALYSIS ON EXISTING DESIGN OF CHASSIS



73




S glass epoxy



The above image shows strain value 0.0000143

FATIGUE ANALYSIS ON EXISTING DESIGN OF CHASSIS



74



STRUCTURAL ANALYSIS ON HONEY COMB DE-SIGN OF CHASSIS

MILD STEEL

The above image is the imported model of chassis. Modeling was done in Pro-E and imported with the help of IGES (Initial Graphical Exchanging Specifi-cation).

RESULTS TABLES

EXISTING

Mild Steel E-Glass S-Glass

Displacement 1.489 4.333 0.360

Stress 12.426 12.398 12.406

Strain 5.928e-5 0.0001715 1.4305 e-5

SafetyFactor = yelidstreng-ht/stress

44.262 40.329 369.57

Biaxiality indication

0.914 0.913 0.9242

Alternative Stress

24.853 24.795 24.812

MODIFIED


Displacement 1.640 4.7729 0.39734

Stress 12.509 12.644 12.531

Strain 6.377 e-5 0.000190 1.5744 e-5


43.968 39.544 365.89


0.99532 0.992 0.9961

Alternative Stress

25.017 25.289 25.2062

HONEY COMB


Displacement 3.4035 9.9334 0.8634

Stress 39.594 40.381 40.154

Strain 0.000194 0.00057333 4.7511 e-5


13.890 12.382 114.18


0.9966 0.99516 0.9969

Alternative Stress

79.188 80.763 80.309

IMPACT ANAYLSIS

MATERIAL: S-GLASS EPOXY

material existing modified Honey comb

displacement 83905 1.3107e5 4.8526e5

stress 16.869 16.917 47.382

strain 0.000021605 0.000021617 0.000054645

CONCLUSION

This thesis works present’s / work’s on “structural optimization of chassis and implementation of com-posite materials in heavy vehicle chassis to reduce the weight without reducing structure quality”.As per the problem description weight is the major part which effect on millage and cost of the chassis.

• Firstliteraturesurvey and data collection was done to understand the rectification method and material selection.• In the next step 3D models of chassis regular and Honey comb is prepared in Pro-E for further study is Ansys.• In the next step structural and fatigue analysis was conducted to find stress locations ,factor of safety and fatigue level’s (Alternating stress) us-ing mild steel,FRP & CRPF along with honey comb structure• In the next step impact test was conducted to find Impact Resistance using S2 – Glass.• As per analytical results Honey comb structure chassis along with S2 –Glass(CRPF) is the best choice.• By using S2-Glass along with honey comb struc-

75


ture weight is reduced up to 75% and quality is im-proved by 87 % .So better to us above suggested model & material.• S2-Glass chassis manufacturing is very easy while compared with Mild steel.

BIBLIOGRAPHY1.1Manpreet singh bajwa, 2yatin raturi, 3amit joshi(1)2.1Hemant kumar nayak, 2nagendra prasad, 3 deepty verma,4tulsi bisht3.Thanneru raghu krishna prasad, gouthamsolasa, nariganani sd satyadeep, g.Sureshbabu4.Hirak patel, khushbu c. Panchal, chetan s. Jadav

5.Hemant b.Patil1, sharad d.Kachave2, eknath r.Deore3 1(p.G.Student mechani-cal, s.Sv.P.S.B.S.D.C.O.Engg, dhule north ma-harashtra university, india) 2(mechanical, s.Sv.P.S.B.S.D.C.O.Engg, dhule north maha-rashtra university, india) 3(head of mechanical, s.Sv.P.S.B.S.D.C.O.Engg, dhule north maharashtra university, india)

6.Prajwal kumar m. P1, vivek muralidharan2, g. Madhusudhana3

7. Haval kamal asker1, thakersalih dawood1 and arkanfawzi said2

8.Mukeshkumar r. Galolia, 2 prof. J. M. Patel9.Sairamkotari 1, v.Gopinath2

10.Mohdazizi muhammad nora,b*, helmirashida, wan mohdfaizul wan mahyuddinb,Mohdazuanmohdazlanc, jamaluddinmahmuda11.Alireza arab solghar*, zeinabarsalanloo12E.Bhaskar 1, t.Muneiah 2, ch.Venkata rajesh313. Haiping du, weihua li, nong zhang, du, h., Li, w. & Zhang,

Authour

K.RajeshResearch Scholar,Department Of Mechanical Engineering,Vikas college of Engineering and Technology, Vijayawada rural,A.P,India

K.DurgaAssistant Professor,Department Of Mechanical Engineering,Vikas college of Engineering and Technology, Vijayawada rural,A.P,India

Education

DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS USING HONEY COMB STRUCTURE