The document summarizes the random vibration and transient bump analysis of an automotive heavy vehicle leveling frame. It describes the modeling, optimization, and structural analysis of the existing leveling frame to reduce its weight. The leveling frame of a TATA 715 vehicle is modeled in SOLIDWORKS and analyzed in ANSYS to validate the optimized design. Various loads acting on the frame are considered and the design is evaluated based on stresses and deformations. The results are studied to validate the weight-reduced leveling frame.
Finite Element Analysis of Fire Truck Chassis for Steel and Carbon Fiber Mate...IJERA Editor
Chassis is the foremost component of an automobile that acts as the frame to support the vehicle body. Hence the frame ought to be very rigid and robust enough to resist shocks vibrations and stresses acting on a moving vehicle. Steel in its numerous forms is commonly used material for producing chassis and overtime alumimium has acquired its use. However, in this study traditional materials are replaced with ultra light weight carbon fiber materials. High strength and low weight of carbon fibers makes it ideal for manufacturing automotive chassis. This paper depicts the modal and static structural analysis of TATA 407 fire truck chassis frame for steel as well as carbon fibers. From the analyzed results, stress, strain and total deformation values were compared for both the materials. Since it is easy to analyze structural systems by finite element method, the chassis is modified using PRO-E and the Finite Element Analysis is performed on ANSYS workbench.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS USING HONEY COMB STRUCTUREIjripublishers Ijri
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
Explicit Dynamic Analysis of Automotive Bus Body Structure During Catastrophi...Davalsab M.L
According to the Accidents investigation for buses and Automotive, Accidents involving frontal crash creates a vital portion among all bus accidents. Through this sort accidents, front body of the bus structure gets severely damages and this puts the drivers and crew in more injury risk. And most of the frontal crash accidents ends up in the death of the driver, as a result of this, the protection of each the driver and also the crew ought to be ensured within the case of frontal crash accidents. To providing the driver safety is crucial since bus driver is that the key person for keeping the control of the bus within the event of accidents in order to that safety of the passengers are going to be ensured.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
Finite Element Analysis of Fire Truck Chassis for Steel and Carbon Fiber Mate...IJERA Editor
Chassis is the foremost component of an automobile that acts as the frame to support the vehicle body. Hence the frame ought to be very rigid and robust enough to resist shocks vibrations and stresses acting on a moving vehicle. Steel in its numerous forms is commonly used material for producing chassis and overtime alumimium has acquired its use. However, in this study traditional materials are replaced with ultra light weight carbon fiber materials. High strength and low weight of carbon fibers makes it ideal for manufacturing automotive chassis. This paper depicts the modal and static structural analysis of TATA 407 fire truck chassis frame for steel as well as carbon fibers. From the analyzed results, stress, strain and total deformation values were compared for both the materials. Since it is easy to analyze structural systems by finite element method, the chassis is modified using PRO-E and the Finite Element Analysis is performed on ANSYS workbench.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS USING HONEY COMB STRUCTUREIjripublishers Ijri
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
Explicit Dynamic Analysis of Automotive Bus Body Structure During Catastrophi...Davalsab M.L
According to the Accidents investigation for buses and Automotive, Accidents involving frontal crash creates a vital portion among all bus accidents. Through this sort accidents, front body of the bus structure gets severely damages and this puts the drivers and crew in more injury risk. And most of the frontal crash accidents ends up in the death of the driver, as a result of this, the protection of each the driver and also the crew ought to be ensured within the case of frontal crash accidents. To providing the driver safety is crucial since bus driver is that the key person for keeping the control of the bus within the event of accidents in order to that safety of the passengers are going to be ensured.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
Study of Different Parameters on the Chassis Space Frame For the Sports Car b...IOSR Journals
The concept of Finite Element Analysis of a chassis space frame has been highlighted in this project.
The topic has constrained the study of the chassis space frame. Complex assemblies are to be avoided, for
sports car. The model of the chassis space frame is built using CATIA V5 and then imported to ANSYS CLASSIC
11.0 to find its finite element module. To perform a torsion and Bending Test on the computational prototype
chassis to determine its torsional stiffness. To incorporate a design improvement study and note the effects on
the global torsional stiffness of the chassis. The stress ,strength and degrees of freedom of the chassis will be
investigated. The body shape is fixed and therefore the overall external shape of the chassis must not be altered.
The engine bay must remain as open as possible to allow a variety of engines to be fitted
Stress analysis on steering knuckle of the automobile steering systemeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Design and fabrication of variable steering ratio mechanism for light Motor v...sushil Choudhary
To facilitate easy and proper steering of the vehicle while negotiating a turn, as per the requirements of driver in
different situations like hair pin bends in hilly regions, sudden turns in highways and city streets or in sports car
during race events an improved steering system is needed to address these problems. The steering arrangement
used in a normal automobile was investigated and to solve the above problems a variable steering ratio
mechanism was designed and fabricated, with the aim to determine if incorporation of variable steering ratio
mechanism will make an improvement in the steady and transient state handling of the automobile. The size of
the pinion gear and the number of teeth on the gear determine the rack-and-pinion steering ratio. The steering
wheel must be turned one revolution to turn the front wheels one sixteenth of a turn, the steering ratio is 1 to
1/16. Reversing the numbers gives a ratio of 16 to 1, or 16:1. This steering ratio is always fixed. A variable
steering ratio mechanism was fabricated by using constant mesh type gears from Bajaj-Super and steering
mechanism from Tata-Nano. Gear housing using wood is created and gear shifting arrangement incorporated. It
was observed that on engaging the 1st gear steering ratio is increased to 9.92:1. On engaging the 2nd gear
steering ratio is increased to 7.20:1, On engaging the 3rd gear steering ratio is increased to 4.96:1 On engaging
the 4th gear steering ratio is increased to 3.52:1. The effort required for steering is increased due to these ratios
as energy is lost due to friction. This mechanism can only be practical if used in conjugation with power assist.
Fatigue or Durability Analysis of Steering Knuckleijsrd.com
the purpose of the study of this thesis is to discuss analysis the acting force upon the steering knuckle while in track or random load for a vehicle. Steering knuckle is main important part in the vehicle because that requires lots of attention in selection because once it is damaged then it have to replace with the new one. Structural Components such as a steering knuckle might be strong enough to withstand a single applied load. But what happens when the part operates over and over, day after today? To predict component failure in such cases requires what's called fatigue or durability analysis. For our purposes, a constant or static load does not cause failure. What counts is the impact of working or fluctuating loads. Failures, or fractures, take place when cracks get so large that remaining material can no longer endure stresses and strains. In classic structural analyses, failure predictions are based solely on material strength or yield strength. Durability analysis goes beyond this, evaluating failure based on repeated simple or complex loading.
In this research work, suitable lightweight material is found for chassis frame by analyzing chassis with different
materials like structural steel, aluminum alloy and Epoxy E-Glass UD composite materials. The selected material should have the
sufficient strength to carry the load coming on to the chassis when it is supporting the vehicle. With reduction in the weight of the
chassis, reduces the overall weight of the vehicle, which leads to the reduction in fuel. Thus, the usage of lightweight materials in
manufacturing of chassis frame has the advantages. The materials used should help in reducing the weight of the vehicle while
maintaining the necessary strength for supporting the expected load acting on the frame under various operating conditions.
ANSYS finite element software is used to analyze the performance of the chassis with different materials. The 3D model of the
chassis frame is developed by SOLIDWORKS software and numerical analysis is carried out by ANSYS. The model of the ladder
frame is developed using generic specifications. The FEM analysis was done on chassis frame for its deformation and stresses by
applying maximum load. The von-misses stresses, strain and deformations of the chassis with structural steel, aluminum alloy and
composite materials are compared. Composite materials are observed to be better with less weight with similar performance. It is
found that composite (E-glass) is more preferable material for chassis frame.
Experimental Investigation of U Bolt used in Leaf Spring of an Automobile for...ijtsrd
Threaded fastener such as U bolts are probably the best choice to apply a desired clamp load to assemble a joint or connection. The main characteristic of holding U bolt of automobile wheel is being under cyclic load which are applied by bumpy rods. So it is necessary to prevent the failure of U bolt under different condition. To do experimental testing for every new design of bolted connection. Hitesh Patil | Dr. S. I. Kolhe "Experimental Investigation of U Bolt used in Leaf Spring of an Automobile for Various Loads" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29140.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29140/experimental-investigation-of-u-bolt-used-in-leaf-spring-of-an-automobile-for-various-loads/hitesh-patil
The goal of the project is to design an electric bike which is suitable for use as a daily commuter. The electric bike is powered by a 2 KW BLDC 48Volts motor with peak rotational speed of 3000 RPM. The rear wheel of the bike is chain driven. By considering factors like power density, weight and cost, Lithium ion batteries of type LiFePO4 Lithium iron phosphate are best suited for electric bike. The position of driver is very crucial as it affects center of gravity, weight distribution and ergonomics of the driver. The sub components of an electric bike are as follows chassis, prime power, propulsion, displays and controls. The modelling software used to develop the frame is Solid works and using solid works various FEA are carried out. The frame structure should be optimized for having a strong and light weight structure by considering load paths, bending moments and stress concentration. B. Praveen Kumar | B. Sushma | Amith.G | Ch. Akhileshwar Reddy | L. Vishal Patel ""Design and Analysis of Electric Bike"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23310.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23310/design-and-analysis-of-electric-bike/b-praveen-kumar
A review on stress analysis and weight reduction of automobile chassiseSAT Journals
Abstract
Chassis is the term used to define the basic structure of the vehicle. It is also referred to as carrying unit as all the units including
body are mounted on it. There are various loads acting on the chassis like inertia loads, static loads, over loads, etc. also it has to
withstand the forces induced due to sudden braking and acceleration. In this paper a review has been made on the stress analysis
of chassis by finite element analysis software packages like ANSYS, HyperWorks, etc. Weight reduction is gaining importance as
the designers are trying to reduce the excess weight form the existing vehicle design. A review of the various techniques for weight
reduction for the chassis is presented.
Keywords: chassis, finite element analysis, weight reduction, ANSYS
Structural and Fatigue Analysis of Two Wheeler Lighter Weight Alloy WheelIOSR Journals
Importance of wheel in the automobile is obvious. The vehicle may be towed without the engine but
at the same time even that is also not possible without the wheels, the wheels along the tire has to carry the
vehicle load, provide cushioning effect and cope with the steering control. Generally wheel spokes are the
supports consisting of a radial member of a wheel joining the hub to the rim. The most commonly used materials
for making Wheel spokes are with features of excellent lightness, thermal conductivity, corrosion resistance,
characteristics of casting, low temperature, high damping property, machine processing and recycling, etc. This
metal main advantage is reduced weight, high accuracy and design choices of the wheel. This metal is useful for
energy conservation because it is possible to re-cycle. Spokes make vehicles look great but at the same time they
require attention in maintenance. To perform their functions best, the spokes must be kept under the right
amount of tension. The two main types of motorcycle rims are solid wheels, in which case the rim and spokes
are all cast as one unit and the other spoke wheels, where the motorcycle rims are laced with spokes. These
types of wheels require unusually high spoke tension, since the load is carried by fewer spokes. If a spoke does
break, the wheel generally becomes instantly unridable also the hub may break. Presently, for motor-cycles
Aluminium alloy wheels are used, currently now replacing by new magnesium alloy due its better properties
than Al-alloy. An important implication of this paper or the problem stated here is to “analyse the stress and the
displacement distribution comparing the results obtained”. In addition, this work extends Proper analysis of the
wheel plays an important role for the safety of the rider. This paper deals with the static &fatigue analysis of the
wheel. The present work attempts to analyse the safe load of the alloy wheel, which will indicate the safe drive is
possible. A typical alloy wheel configuration of Suzuki GS150R commercial vehicle is chosen for study. Finite
element analysis has been carried out to determine the safe stresses and pay loads
Design and analysis of an electric karteSAT Journals
Abstract This paper presents the design and analysis of an electric motor powered kart. The main aim of this paper is to reduce the usage of organic fuel powered vehicles and to design a vehicle which works efficiently in the emerging electric vehicle sector. In order to maintain the speed levels of the kart, seamless decision was made in motor selection. Alternate materials have been applied in the kart to reduce both static and dynamic forces in pursuance of improving the efficiency and performance of the kart. Detailed design of subsystems like chassis frame, steering system, electrical power train and braking mechanism has been done effectively. The main focus of the frame design was on the stability of the kart and safety of the driver. The CAD model of the kart was done in CREO 2.0. Aluminium alloy 6063 has been employed for the frame to reduce the overall weight. To check the feasibility of the frame design, finite element analysis has been done using ANSYS 14.5. The results obtained showed that the frame design was safe under maximal impact load conditions. Weight reduction was a major concern and hence linkage type steering was selected for the kart. Motor, the heart of the electric vehicle was selected and installed in such a way that it can perform well for an extended run time. PMDC motor was selected in this case. Speed control of the kart was done using a voltage controller. The kart is provided with a timing belt drive to achieve maximum efficiency in transmission of power from the motor to the wheels. Hydraulic disc brakes were provided for smooth and effective braking under both dry and wet conditions. Slick tires are used to provide more traction. Design calculations were carried out and optimum results were obtained. An extensive market survey was also done on frame material, brakes, motor, transmission system for cost and availability. International standards were followed throughout the design process. Keywords: Stability, Frame, Finite Element Analysis, PMDC Motor, Timing belt
IN THIS BOOK DETAILS OF AUTOMOBILE CHASSIS BOOK
contents
1.0 Chassis, Frame and Body
1.1 Introduction of Chassis frame
1.2 Layout of the Chassis and its main components
1.3 Functions of the Chassis frame
1.4 Types of Chassis frames
1.5 Various loads acting on the frame
1.6 State the different bodies used in automobiles
1.7 Explain the requirements of bodies for various types of
vehicles viz. private, commercial etc.
2.0 Steering Sytem
2.1 Requirement of the Vehicle steering
2.2 Types of Steering ears, systems and power steering
2.3 Steering linkages mechanism under steering, over steering
2.4 Turning radius
2.5 Wheel alignment of Ackerman’s & Devis Steering gear,
Mechanism
2.6 Steering geometry – Caster, Camber, King pin inclination, toe
in and toe out
2.7 Steering defects – wheel woubble and shimmy
2.8 List our the type of steering system used in various vehicles
3.0 Braking system
3.1 Explain Functions of brakes
3.2 Requirements of automobile brakes
3.3 Explain stopping time and stopping distance
3.4 Type of Braking systems – Disc and Drum braking system
3.5 Construction and working of Mechanical, hydraulic, and air
brakes
3.6 List out the types of brakes used in various vehicles
4.0 Suspension System
4.1 Requirement of a automobile suspension system
4.2 Types of suspension system – conventional and Independent
4.3 Types of springs – Laminated spring, coil spring, helical spring
4.4 Need of Shock absorber – construction and working of
different types of shock absorbers
4.5 Stabilizer bar and torsion bar
4.6 List out the type of suspension system used in various vehicles
5.0 Seat, Door and Window mechanism
5.1 Construction and working of door lock mechanism
5.2 Construction and working of manual window regulating
mechanism
5.3 Construction and working of power window regulating
mechanism
5.4 Construction and working of seat adjusting mechanism
6.0 Air Conditioning of motor vehicles
6.1 Necessity of automobile air conditioning
6.2 Construction and working of passenger car air conditioning
7.0 Painting of automobiles
7.1 Body painting
7.2 Different types of painting – Spray painting – hand painting
procedures
8.0 Automobile Pollution
8.1 Effects of automobile pollution on environment and human
beings
8.2 Types of automobile emissions
8.3 Treatment of exhaust gases by using catalytic convectors
8.4 Measurement of percentage of pollutants from petrol &
Diesel vehicles with the help of exhaust gas analyzers
9.0 Legal aspects of motor vehicles
9.1 Traffic signs and signals
9.2 Registration requirements
9.3 Necessity of permits for commercial vehicles
9.4 Insurance coverage
9.5 Procedure for obtaining driving licenses
Study of Different Parameters on the Chassis Space Frame For the Sports Car b...IOSR Journals
The concept of Finite Element Analysis of a chassis space frame has been highlighted in this project.
The topic has constrained the study of the chassis space frame. Complex assemblies are to be avoided, for
sports car. The model of the chassis space frame is built using CATIA V5 and then imported to ANSYS CLASSIC
11.0 to find its finite element module. To perform a torsion and Bending Test on the computational prototype
chassis to determine its torsional stiffness. To incorporate a design improvement study and note the effects on
the global torsional stiffness of the chassis. The stress ,strength and degrees of freedom of the chassis will be
investigated. The body shape is fixed and therefore the overall external shape of the chassis must not be altered.
The engine bay must remain as open as possible to allow a variety of engines to be fitted
Stress analysis on steering knuckle of the automobile steering systemeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Design and fabrication of variable steering ratio mechanism for light Motor v...sushil Choudhary
To facilitate easy and proper steering of the vehicle while negotiating a turn, as per the requirements of driver in
different situations like hair pin bends in hilly regions, sudden turns in highways and city streets or in sports car
during race events an improved steering system is needed to address these problems. The steering arrangement
used in a normal automobile was investigated and to solve the above problems a variable steering ratio
mechanism was designed and fabricated, with the aim to determine if incorporation of variable steering ratio
mechanism will make an improvement in the steady and transient state handling of the automobile. The size of
the pinion gear and the number of teeth on the gear determine the rack-and-pinion steering ratio. The steering
wheel must be turned one revolution to turn the front wheels one sixteenth of a turn, the steering ratio is 1 to
1/16. Reversing the numbers gives a ratio of 16 to 1, or 16:1. This steering ratio is always fixed. A variable
steering ratio mechanism was fabricated by using constant mesh type gears from Bajaj-Super and steering
mechanism from Tata-Nano. Gear housing using wood is created and gear shifting arrangement incorporated. It
was observed that on engaging the 1st gear steering ratio is increased to 9.92:1. On engaging the 2nd gear
steering ratio is increased to 7.20:1, On engaging the 3rd gear steering ratio is increased to 4.96:1 On engaging
the 4th gear steering ratio is increased to 3.52:1. The effort required for steering is increased due to these ratios
as energy is lost due to friction. This mechanism can only be practical if used in conjugation with power assist.
Fatigue or Durability Analysis of Steering Knuckleijsrd.com
the purpose of the study of this thesis is to discuss analysis the acting force upon the steering knuckle while in track or random load for a vehicle. Steering knuckle is main important part in the vehicle because that requires lots of attention in selection because once it is damaged then it have to replace with the new one. Structural Components such as a steering knuckle might be strong enough to withstand a single applied load. But what happens when the part operates over and over, day after today? To predict component failure in such cases requires what's called fatigue or durability analysis. For our purposes, a constant or static load does not cause failure. What counts is the impact of working or fluctuating loads. Failures, or fractures, take place when cracks get so large that remaining material can no longer endure stresses and strains. In classic structural analyses, failure predictions are based solely on material strength or yield strength. Durability analysis goes beyond this, evaluating failure based on repeated simple or complex loading.
In this research work, suitable lightweight material is found for chassis frame by analyzing chassis with different
materials like structural steel, aluminum alloy and Epoxy E-Glass UD composite materials. The selected material should have the
sufficient strength to carry the load coming on to the chassis when it is supporting the vehicle. With reduction in the weight of the
chassis, reduces the overall weight of the vehicle, which leads to the reduction in fuel. Thus, the usage of lightweight materials in
manufacturing of chassis frame has the advantages. The materials used should help in reducing the weight of the vehicle while
maintaining the necessary strength for supporting the expected load acting on the frame under various operating conditions.
ANSYS finite element software is used to analyze the performance of the chassis with different materials. The 3D model of the
chassis frame is developed by SOLIDWORKS software and numerical analysis is carried out by ANSYS. The model of the ladder
frame is developed using generic specifications. The FEM analysis was done on chassis frame for its deformation and stresses by
applying maximum load. The von-misses stresses, strain and deformations of the chassis with structural steel, aluminum alloy and
composite materials are compared. Composite materials are observed to be better with less weight with similar performance. It is
found that composite (E-glass) is more preferable material for chassis frame.
Experimental Investigation of U Bolt used in Leaf Spring of an Automobile for...ijtsrd
Threaded fastener such as U bolts are probably the best choice to apply a desired clamp load to assemble a joint or connection. The main characteristic of holding U bolt of automobile wheel is being under cyclic load which are applied by bumpy rods. So it is necessary to prevent the failure of U bolt under different condition. To do experimental testing for every new design of bolted connection. Hitesh Patil | Dr. S. I. Kolhe "Experimental Investigation of U Bolt used in Leaf Spring of an Automobile for Various Loads" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29140.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29140/experimental-investigation-of-u-bolt-used-in-leaf-spring-of-an-automobile-for-various-loads/hitesh-patil
The goal of the project is to design an electric bike which is suitable for use as a daily commuter. The electric bike is powered by a 2 KW BLDC 48Volts motor with peak rotational speed of 3000 RPM. The rear wheel of the bike is chain driven. By considering factors like power density, weight and cost, Lithium ion batteries of type LiFePO4 Lithium iron phosphate are best suited for electric bike. The position of driver is very crucial as it affects center of gravity, weight distribution and ergonomics of the driver. The sub components of an electric bike are as follows chassis, prime power, propulsion, displays and controls. The modelling software used to develop the frame is Solid works and using solid works various FEA are carried out. The frame structure should be optimized for having a strong and light weight structure by considering load paths, bending moments and stress concentration. B. Praveen Kumar | B. Sushma | Amith.G | Ch. Akhileshwar Reddy | L. Vishal Patel ""Design and Analysis of Electric Bike"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23310.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23310/design-and-analysis-of-electric-bike/b-praveen-kumar
A review on stress analysis and weight reduction of automobile chassiseSAT Journals
Abstract
Chassis is the term used to define the basic structure of the vehicle. It is also referred to as carrying unit as all the units including
body are mounted on it. There are various loads acting on the chassis like inertia loads, static loads, over loads, etc. also it has to
withstand the forces induced due to sudden braking and acceleration. In this paper a review has been made on the stress analysis
of chassis by finite element analysis software packages like ANSYS, HyperWorks, etc. Weight reduction is gaining importance as
the designers are trying to reduce the excess weight form the existing vehicle design. A review of the various techniques for weight
reduction for the chassis is presented.
Keywords: chassis, finite element analysis, weight reduction, ANSYS
Structural and Fatigue Analysis of Two Wheeler Lighter Weight Alloy WheelIOSR Journals
Importance of wheel in the automobile is obvious. The vehicle may be towed without the engine but
at the same time even that is also not possible without the wheels, the wheels along the tire has to carry the
vehicle load, provide cushioning effect and cope with the steering control. Generally wheel spokes are the
supports consisting of a radial member of a wheel joining the hub to the rim. The most commonly used materials
for making Wheel spokes are with features of excellent lightness, thermal conductivity, corrosion resistance,
characteristics of casting, low temperature, high damping property, machine processing and recycling, etc. This
metal main advantage is reduced weight, high accuracy and design choices of the wheel. This metal is useful for
energy conservation because it is possible to re-cycle. Spokes make vehicles look great but at the same time they
require attention in maintenance. To perform their functions best, the spokes must be kept under the right
amount of tension. The two main types of motorcycle rims are solid wheels, in which case the rim and spokes
are all cast as one unit and the other spoke wheels, where the motorcycle rims are laced with spokes. These
types of wheels require unusually high spoke tension, since the load is carried by fewer spokes. If a spoke does
break, the wheel generally becomes instantly unridable also the hub may break. Presently, for motor-cycles
Aluminium alloy wheels are used, currently now replacing by new magnesium alloy due its better properties
than Al-alloy. An important implication of this paper or the problem stated here is to “analyse the stress and the
displacement distribution comparing the results obtained”. In addition, this work extends Proper analysis of the
wheel plays an important role for the safety of the rider. This paper deals with the static &fatigue analysis of the
wheel. The present work attempts to analyse the safe load of the alloy wheel, which will indicate the safe drive is
possible. A typical alloy wheel configuration of Suzuki GS150R commercial vehicle is chosen for study. Finite
element analysis has been carried out to determine the safe stresses and pay loads
Design and analysis of an electric karteSAT Journals
Abstract This paper presents the design and analysis of an electric motor powered kart. The main aim of this paper is to reduce the usage of organic fuel powered vehicles and to design a vehicle which works efficiently in the emerging electric vehicle sector. In order to maintain the speed levels of the kart, seamless decision was made in motor selection. Alternate materials have been applied in the kart to reduce both static and dynamic forces in pursuance of improving the efficiency and performance of the kart. Detailed design of subsystems like chassis frame, steering system, electrical power train and braking mechanism has been done effectively. The main focus of the frame design was on the stability of the kart and safety of the driver. The CAD model of the kart was done in CREO 2.0. Aluminium alloy 6063 has been employed for the frame to reduce the overall weight. To check the feasibility of the frame design, finite element analysis has been done using ANSYS 14.5. The results obtained showed that the frame design was safe under maximal impact load conditions. Weight reduction was a major concern and hence linkage type steering was selected for the kart. Motor, the heart of the electric vehicle was selected and installed in such a way that it can perform well for an extended run time. PMDC motor was selected in this case. Speed control of the kart was done using a voltage controller. The kart is provided with a timing belt drive to achieve maximum efficiency in transmission of power from the motor to the wheels. Hydraulic disc brakes were provided for smooth and effective braking under both dry and wet conditions. Slick tires are used to provide more traction. Design calculations were carried out and optimum results were obtained. An extensive market survey was also done on frame material, brakes, motor, transmission system for cost and availability. International standards were followed throughout the design process. Keywords: Stability, Frame, Finite Element Analysis, PMDC Motor, Timing belt
IN THIS BOOK DETAILS OF AUTOMOBILE CHASSIS BOOK
contents
1.0 Chassis, Frame and Body
1.1 Introduction of Chassis frame
1.2 Layout of the Chassis and its main components
1.3 Functions of the Chassis frame
1.4 Types of Chassis frames
1.5 Various loads acting on the frame
1.6 State the different bodies used in automobiles
1.7 Explain the requirements of bodies for various types of
vehicles viz. private, commercial etc.
2.0 Steering Sytem
2.1 Requirement of the Vehicle steering
2.2 Types of Steering ears, systems and power steering
2.3 Steering linkages mechanism under steering, over steering
2.4 Turning radius
2.5 Wheel alignment of Ackerman’s & Devis Steering gear,
Mechanism
2.6 Steering geometry – Caster, Camber, King pin inclination, toe
in and toe out
2.7 Steering defects – wheel woubble and shimmy
2.8 List our the type of steering system used in various vehicles
3.0 Braking system
3.1 Explain Functions of brakes
3.2 Requirements of automobile brakes
3.3 Explain stopping time and stopping distance
3.4 Type of Braking systems – Disc and Drum braking system
3.5 Construction and working of Mechanical, hydraulic, and air
brakes
3.6 List out the types of brakes used in various vehicles
4.0 Suspension System
4.1 Requirement of a automobile suspension system
4.2 Types of suspension system – conventional and Independent
4.3 Types of springs – Laminated spring, coil spring, helical spring
4.4 Need of Shock absorber – construction and working of
different types of shock absorbers
4.5 Stabilizer bar and torsion bar
4.6 List out the type of suspension system used in various vehicles
5.0 Seat, Door and Window mechanism
5.1 Construction and working of door lock mechanism
5.2 Construction and working of manual window regulating
mechanism
5.3 Construction and working of power window regulating
mechanism
5.4 Construction and working of seat adjusting mechanism
6.0 Air Conditioning of motor vehicles
6.1 Necessity of automobile air conditioning
6.2 Construction and working of passenger car air conditioning
7.0 Painting of automobiles
7.1 Body painting
7.2 Different types of painting – Spray painting – hand painting
procedures
8.0 Automobile Pollution
8.1 Effects of automobile pollution on environment and human
beings
8.2 Types of automobile emissions
8.3 Treatment of exhaust gases by using catalytic convectors
8.4 Measurement of percentage of pollutants from petrol &
Diesel vehicles with the help of exhaust gas analyzers
9.0 Legal aspects of motor vehicles
9.1 Traffic signs and signals
9.2 Registration requirements
9.3 Necessity of permits for commercial vehicles
9.4 Insurance coverage
9.5 Procedure for obtaining driving licenses
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Recent Developments and Analysis of Electromagnetic Metamaterial with all of ...IOSR Journals
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devices with electromagnetic functionality. The metamaterial have the power which can easily construct
materials with a user-designed EM response with a particular target frequency. This is the important
phenomena of THz frequency region that can make a considerable progress in design fabrication, and define the
characteristics of MMs at THz frequencies. This article illustrates the latest advancements of THz MMs
research.
Key word: Metamaterials (MMs), Terahertz (THz).
Spectral Studies of Some Transition Metal Ion complexes with 4-[(E)-(Ferrocen...IOSR Journals
Several new complexes of some transition metal ions with organometallic compounds were derived from ferrocencecarboxylaldehyde and 4-amino-2-hydroxy pyridine. These organometallic complexes were investigated by using some analytical techniques like infrared, mass spectra, electronic spectra, electron spin resonance, thermal analysis, magnetic moment, conductivity and antimicrobial activity. From the obtained elemental analysis data, organometallic compounds complexes shows 1:2 [M: L] ratio and general formula of the complex is [ML2.2H2O]. These complexes revealed a non-electrolytic nature. The magnetic moment values of the complexes exhibited the paramagnetic as well as diamagnetic in nature. The coordination behavior of the metal ions towards to the investigated organometallic compounds takes place through >C=N- and –OH groups. The electronic spectral data shows that all the complexes are covalent in nature, octahedral structure with co-ordination number six. Organometallic compound complexes were loses two water molecules subjected to simultaneous thermo gravimetric analysis, to study their decomposition mechanism and thermal stability. Mass spectra of the organometallic compound and their complexes are matched with theoretical values of the masses. The prepared organometallic compounds and their metal complexes were screened for their antibacterial activity against some bacterial species, Escherichia coli, Pseudomonas aeruginosa and Staphylococcus Pyogones. The Antimicrobial activity data show the metal complexes to be more active than the parent organometallic compounds.
Increase In Electrical And Thermal Conductivities Of Doped Polymers Dependent...IOSR Journals
Most Polymers do not possess natural intrinsic properties that will be enough for them to be used as semi- conductors. In the world trend of industrial growth where polymers seem to be replacing all semi-conductors because of their availability, durability, recyclability and reduced cost, attention is being strongly given to their improvement them for this essential function hence the need for this research.Eight samples each of four polymers; polyethylene (PE), polystyrene (PS), poly propylene (PP),nylon 66 were prepared by doping with different concentrationsof graphite to enhance their electrical and thermal conductivities, considering the fact that they are of different intrinsic properties. The samples were testedfor their electrical and thermal conductivities.It was evident that as the concentration of the graphite dopantincreases, the electrical and thermal conductivities of all the polymers increased although not at the same rate.The most interesting fact is that all polymers that showed highly favorable results in electrical conductivity, showed the least for thermal conductivities which can be attributed to their intrinsic properties.
A Review: Machine vision and its ApplicationsIOSR Journals
Abstract:The machine vision has been used in the industrial machine designing by using the intelligent character recognition. Due to its increased use, it makes the significant contribution to ensure the competitiveness in modern development. The state of art in machine vision inspection and a critical overview of applications in various industries are presented in this paper. In its restricted sense it is also known as the computer vision or the robot vision. This paper gives the overview of Machine Vision Technology in the first section, followed by various industrial application and thefuture trends in Machine Vision. Keywords:CCD- charged coupled devices, Fruit harvesting system, HIS- Hue Saturation Intensity, Image analysis, Image enhancement, Image feature extraction, Image feature classification processing, Intelligent Vehicle tracking , Isodiscriminationn Contour, Machine Vision
Structural Analysis of Ladder Chassis Frame for Jeep Using Ansys IJMER
Automotive chassis frame is an important part of an automobile. The automotive chassis
frame is the structural backbone of any vehicle. The main function of chassis frame is to support the
body, different parts of an automobile and topayload placed upon it.The chassis frame has to withstand
the stresses developed as well as deformation occurs in it and to withstand the shock, twist vibration
and other stresses. Its principle function is to carry the maximum load for all designed operating
condition safelythat should be within a limit. On chassis, frame maximum shear stress and deflection
under maximum load are important criteria for design andanalysis. In these projects, we
havecalculated the von mises stress and shear stress for the chassis frame and the finite element
analysis has been donefor the validation on the chassis frame model of jeep. We have taken certain
material as Mild sheet steel, aluminium alloy and titanium alloy for the rectangular hollow box type to
design chassis frame of jeep.
Software used in this project, CATIA V5-[Product 1] for design purpose and ANSYS 14 is used for
analysis.
Engine is one of the most significant component of road vehicles. High performance vehicles have their
engine supported by bracket. The engine mounting plays an important role in reducing the noise and vibrations, improving the
comfort and work environment of a vehicle. The present work deals with design modification of engine mounting bracket.
Modelling work has been carried out with commercial desktop CAD software and analyzed the modal performance with
Analysis software. Ribs has been adopted to the existing mounting bracket for its better performance structural, thermal and
modal analysis has been carried out with analysis software. Aluminium alloy, aluminium silicon carbide and magnesium alloy
are considered as the different materials of mounting bracket. Based on the analysis it is found that the aluminium silicon
carbide is superior suited for the modified V6 engine mounting bracket.
Optimization study on trailer arm chassis by finite element methodeSAT Journals
Abstract: Chassis is the important part of an automobile. It supports the body and different parts of an automobile. Chassis consists of engine, brakes, power train, steering system and wheels mounted on a frame. Ƭhe frame is the main part of the chassis on which remaining parts of chassis are placed. Ƭhe chassis should be rigid enough to withstand the twist, shock, stresses, vibrations and bending moments to which it is subjected while vehicle is moving on road. Ƭhe trailer arm chassis frame has to carry and sustain the heavy loads which are applied on it. Hence it is very important to design and analysis of the trailer arm chassis frame. Ƭhe design of trailer arm chassis is carried out by taking the base model structure of chassis as a standard. The optimization technique to redesign Chassis (Frame) of a trailer is carried out here. The trailer had dimensional limits and must be able to reduce the overall size and shape and still lift the same amount of load. Different load cases with given boundary conditions & loadings are used. Ƭo improve the performance of the chassis finite element analysis is carried for various alternatives. Ƭhe analysis is performed by varying the thickness, shape and material to get the best possible design of the chassis. Static analysis is carried out for both basic and modified designs to determine the high stress regions, maximum displacement, and normal stress at critical positions of the chassis. Normal modal analysis for base model is carried out to find the first natural frequency. Normal modal analysis is carried out for all modified designs to improve the first natural frequency of the chassis in order to avoid the resonance. The whole challenging task, starting with pre processing, analysis and post processing is completed using Altair’s HyperMesh, Abaqus and HyperView FE package. Key Words: Trailer arm chassis, Static analysis and Modal analysis.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Design analysis of the roll cage for all terrain vehicleeSAT Journals
Abstract We have tried to design an all terrain vehicle that meets international standards and is also cost effective at the same time. We have focused on every point of roll cage to improve the performance of vehicle without failure of roll cage. We began the task of designing by conducting extensive research of ATV roll cage through finite element analysis. A roll cage is a skeleton of an ATV. The roll cage not only forms the structural base but also a 3-D shell surrounding the occupant which protects the occupant in case of impact and roll over incidents. The roll cage also adds to the aesthetics of a vehicle. The design and development comprises of material selection, chassis and frame design, cross section determination, determining strength requirements of roll cage, stress analysis and simulations to test the ATV against failure. Keywords: Roll cage, material, finite element analysis, strength
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This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
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F012463754
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 4 Ver. VI (Jul. - Aug. 2015), PP 37-54
www.iosrjournals.org
DOI: 10.9790/1684-12463754 www.iosrjournals.org 37 | Page
Random Vibration and Transient Bump Analysis of Automotive
Heavy Vehicle Levelling frame
1
Asst Prof.B.Anil Kumar, 2
S.Sheshikanth Reddy, 3
Prof. VVRLS Gangadhar,
4
Associate Prof.Anoop Kumar
1
Asst Professor, Department of Mechanical Engineering, Princeton College of Engineering & Technology,
Hyderabad, India.
2
M.Tech Student, Department of Mechanical Engineering, Princeton College of Engineering & Technology,
Hyderabad, India.
3
Professor, Department of Mechanical Engineering, Princeton College of Engineering & Technology,
Hyderabad, India.
4
Associate Professor, Department of Mechanical Engineering, JBIET College of Engineering & Technology,
Hyderabad, India.
Abstract: A heavy vehicle automobile is equipped with body and chassis. The chassis is basic structure of a
vehicle. It contains all the engine parts and power systems and the frame is the main portion of chassis on which
the entire load will be mounted. For efficient usage of the frame space and to ease the mounting of required
equipment and maintain the horizontal leveling of them, a suitable frame is designed. This paper describes
design modeling optimization and structural analysis of heavy vehicle levelling frame. Weight reduction is the
prime objective of this paper through analysis. In the present work, the existing heavy vehicle levelling frame is
studied and redesigned. The new leveling frame is validated through analysis using ANSYS. TATA 715 vehicle is
taken for modeling and analysis. The vehicle leveling frame is modeled in SOLID WORKS 2014 and then it is
imported to ANSYS 15.0. The analysis is done with the new frame with all the loads being considered. The
design constraints are stresses and deformations. The results is studied to validate the optimized leveling frame.
Keywords: Levelling frame, Auto CAD 2014, SOLID WORKS 2014, ANSYS 15.0, TATA 715
I. Introduction
Automotive chassis is a French word that was initially used to represent the basic structure. It is a
skeletal frame on which various mechanical parts like engine, tires, axle assemblies, brakes, steering etc. are
bolted. It gives strength and stability to the vehicle under different conditions. At the time of manufacturing, the
body of a vehicle is flexibly molded according to the structure of chassis. Automobile chassis is usually made of
light sheet metal or composite plastics. It provides strength needed for supporting vehicular components and
payload placed upon it. Automotive chassis or automobile chassis helps keep an automobile rigid, stiff and
unbending. It ensures low levels of noise, vibrations and harshness throughout the automobile. Automobile
chassis without the wheels and other engine parts is called frame. Automobile frames provide strength and
flexibility to the automobile. The backbone of any automobile, it is the supporting frame to which the body of an
engine, axle assemblies are affixed. Tie bars that are essential parts of automotive frames are fasteners that bind
different auto parts together. Automotive frames are basically manufactured from steel. Aluminum is another
raw material that has increasingly become popular for manufacturing these auto frames. In an automobile, front
frame is a set of metal parts that forms the framework which also supports the front wheels.
1.1 Types of frames:
There are three types of frames
1. Conventional frame
2. Integral frame
3. Semi-integral frame
1.1.1 Conventional frame It has two long side members and 5 to 6 cross members joined together with the help
of rivets and bolts. The frame sections are used generally. a. Channel Section – Good resistance to bending b.
Tabular Section – Good resistance to Torsion c. Box Section – Good resistance to both bending and Torsion
1.1.2 Integral frame This frame is used now in most of the cars. There is no frame and all the assembly units
are attached to the body. All the functions of the frame carried out by the body itself. Due to elimination of long
frame it is cheaper and due to less weight most economical also. Only disadvantage is repairing is difficult.
2. Random vibration and Transient Bump Analysis of Automotive Heavy Vehicle…
DOI: 10.9790/1684-12463754 www.iosrjournals.org 38 | Page
1.1.3 Semi – Integral frame In some vehicles half frame is fixed in the front end on which engine gear box and
front suspension is mounted. It has an advantage when the vehicle is met with an accident the front frame can be
taken easily to replace the damaged chassis frame. This type of frame is used in American and European cars.
1.2 Functions of the 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 with stand the forces caused due to the sudden braking or acceleration.
4. To with stand the stresses caused due to the bad road condition.
5. To with stand centrifugal force while cornering.
1.3 Various loads acting on the frame
1. Short duration Load – While crossing a broken patch.
2. Momentary duration Load – While taking a curve.
3. Impact Loads – Due to the collision of the vehicle.
4. Inertia Load – While applying brakes.
5. Static Loads – Loads due to chassis parts.
II. Problem Specification
Weight reduction is now the main issue in automobile industries. Because if the weight of the vehicle
increases the fuel consumption increases. At the same time as the weight of the vehicle increases the cost also
increases which becomes a major issue while purchasing an automobile. The frame considered here is an
additional frame apart from vehicle chassis frame which will serve the main purpose of levelling and also
mounting of all the required equipment. It is manufactured with Structural Steel. The equipment that are
mounted on the leveling frame comprises of masts(2 No‘s) upon which high precision antennae will be
mounted, shelter, and leveling jacks(4 No‘s). The conventional frame is designed with more factor of safety and
less regard to the weight and hence the new frame will cater to the load distribution and also keeping acceptable
factor of safety limits in to consideration. Structural, Random vibration and Transient analysis are performed on
the leveling frame in order to ascertain the factor of safety limits.
2.1 Specifications of Existing Heavy Vehicle TATA 1109 EX2 Frame
Sl. No. Description Dimension (mm)
1 Length 3825
2 Width 2300
3 Height 75
4 Weight of conventional frame 660 Kg.
5 Material Structural Steel Mild
1. Structural Steel : Material Data
TABLE1: Structural Steel Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m
TABLE2: Structural Steel Compressive Yield Strength
Compressive Yield Strength Pa
2.5e+008
TABLE3: Structural Steel Tensile Yield Strength
Tensile Yield Strength Pa
2.5e+008
TABLE4: Structural Steel Tensile Ultimate Strength
Tensile Ultimate Strength Pa
4.6e+008
3. Random vibration and Transient Bump Analysis of Automotive Heavy Vehicle…
DOI: 10.9790/1684-12463754 www.iosrjournals.org 39 | Page
TABLE5: Structural Steel Strain-Life Parameters
Strength
Coefficient Pa
Strength
Exponent
Ductility
Coefficient
Ductility
Exponent
Cyclic Strength
Coefficient Pa
Cyclic Strain
Hardening
Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2
TABLE6: Structural Steel Isotropic Elasticity
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
2.e+011 0.3 1.6667e+011 7.6923e+010
TABLE7: Structural Steel Isotropic Relative Permeability
Relative Permeability
10000
2.1 Figure showing assembly of conventional frame on the Truck
2.2 Figure showing Conventional frame
2.3 Figure showing new modified levelling frame
4. Random vibration and Transient Bump Analysis of Automotive Heavy Vehicle…
DOI: 10.9790/1684-12463754 www.iosrjournals.org 40 | Page
2.4 Figure showing new modified levelling frame assembled on the truck
III. Design
Design may be done in two ways one way is the component design which is done by improving the
existing ones. The other is conceptual design where there is no reference and creation of new machines. A new
or better machine is one which is more economical in the overall cost of production and operation. The process
of design is a long and time consuming one. From the study of existing ideas, a new idea has to be conceived.
The idea is then studied keeping in mind its commercial success and given shape and form in the form of
drawings. In the preparation of these drawings, care must be taken about the availability of resources like
money, man power and materials required for the successful completion of the new idea into an actual reality. In
designing a machine component, it is necessary to have a good knowledge of many subjects such as
Mathematics, Engineering Mechanics, Strength of Materials, Theory of Machines, Workshop Processes and
Engineering Drawing. Generally the design of a component involves various steps in it. Initially, the drawings
must be drawn in user friendly software and they must be converted into a 3D model. This 3D model must be
imported into an analyzing medium where it is structurally or thermally analyzed to sustain the need. Different
steps involved in designing a component are
1. Part drawing
2. Modeling
3. Structural analysis
The present frame is divided in to individual components and each component is drawn, modeled and
structurally analyzed by using software and its procedure is explained as below.
3.1 Part Drawing: It is a document that includes the specifications for a part's production. Generally the part
drawings are drawn to have a clear idea of the model to be produced. The part drawing of the entire frame is
drawn with all the views in AUTO CAD 2014.
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3.2 Modeling
It is the process of developing a mathematical representation of any three-dimensional surface of object via
specialized software. The product is called a 3D model.
There are three basic types of three dimensional computer geometric modeling methods
1. Wire frame modeling
2. Surface modeling
3. Solid modeling
3.2.1 Wire Frame Modeling
A wire frame model is visual presentation of a 3 dimensional or physical object used in 3D computer
graphics. It is created by specifying each edge of the physical object where two mathematically continuous
smooth surfaces meet, or by connecting an object‘s constituent vertices using straight lines or curves. The object
is projected on to a display screen by drawing lines at the location of each edge. The wire frame format is well
suited and widely used in programming tool paths for DNC (Direct Numerical Control) machine tools.
3.2.2 Surface Modeling
These models are with no thickness. These models are widely used in industries like automobiles,
aerospace, plastic, medical and so on. Surface models should not be confused with thick models that are models
having mass properties. The only difference between the soli model and the surface model is solid model will
have mass properties. The present frame is modeled by solid modeling because of its ease in construction and
realistic profile.
3.2.3 Solid Modeling
A solid model of an object is a more complete representation than its surface (wireframe) model. It
provides more topological information in addition to the geometrical information which helps to represent the
solid unambiguously. There are different software that are used for generating these solid models like Solid
works and Pro.E. In this project the frame is modeled by using SOLID WORKS 2014. All the parts that are
required for constructing the frame are modeled in part module by using different commands like extrude,
rotate, loft, fillet, extrude cut etc..,
3.3 Assembly
The components that are generated in part module are imported to assembly module and by using
‗insert components‘ command and all these components are mated together to form the required assembly.
3.4 Structural Analysis of the frame:
It is the methodology of determining the effects of loads on physical structures and their components.
Structures subject to this type of analysis include buildings, bridges, vehicles, machinery, furniture, attire, soil
strata, prostheses and biological tissue. Structural analysis incorporates the fields of applied mechanics,
materials science and applied mathematics to compute a structure's deformations, internal forces, stresses,
support reactions, accelerations, and stability. The results of the analysis are used to verify a structure's fitness
for use, often saving physical tests. Structural Analysis is thus a key part of the engineering design of structures.
The present frame model is imported to ANSYS Workbench 15.0 through the interface link established in the
SOLIDWORKS 2014 software. There are various steps that are to be followed in analyzing a component
structurally. They are
1. Mesh generation
2. Fixed supports
3. Application of loads
4. Evaluating result
3.4.1 Mesh Generation
The process for generating a mesh consists of three general steps
1. Set the element attributes
2. Set mesh controls (optional)
3. Meshing the model
It is not always necessary to set mesh controls because the default mesh controls are appropriate for
many models. If no controls are specified, the program will use the default settings (DESIZE) to produce a free
mesh. Alternatively, you can use the advanced Size feature controls to produce a better quality free mesh.
ANSYS Meshing technology provides multiple methods to generate a pure hex or hex- dominant mesh.
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Depending on the model complexity, desired mesh quality and type, and the time available to perform meshing,
ANSYS Meshing provides a scalable solution. Quick automatic hex or hex-dominant mesh can be generated for
optimal solution efficiency and accuracy.
Structural analysis is divided in to two parts:
1. Static Structural analysis: Here loads will be static and does not vary with time. i.e., loads are applied on the
structure and the steady state response of the structure is observed.
2. Dynamic Structural analysis: Loads in this case vary over a period of time. i.e, both frequency and
amplitude of the loads are varied to evaluate the response of the structure. To account for these variations
Random and Transient dynamic analysis are performed.
The Dynamic structural analysis performed here are:
Modal analysis: For calculating the natural frequencies and mode shapes of the structure.
A modal analysis typically is used to determine the vibration characteristics (natural frequencies and
mode shapes) of a structure or machine component in the design stage. It also can serve as a starting point for
another more-detailed dynamic analysis, such as harmonic response or full transient dynamic analysis
Random Vibration Analysis:
Random vibration analyses are used to determine the response of structures to random or time
dependent loading conditions, such as earthquakes, wind loads, ocean wave loads, jet engine thrust, rocket
motor vibrations, and more. The random vibration analysis can be much less computationally intensive than a
full transient dynamic analysis while still providing design-guiding results.
Types of random vibration analyses include:
Response spectrum: single and multi-point base excitation in which the results of a modal analysis are used
with a known spectrum to calculate the model‘s displacements and stresses
Dynamic design analysis method (DDAM): a technique used to evaluate the shock resistance of shipboard
equipment. It is similar to the response spectrum method except the loading is derived from empirical equations
and shock design tables.
Power spectral density: a statistical-based random vibration method in which the input load histories are
specified based on a probability distribution of the loading taking that particular value. An example application
is the calculation of the probable response of a sensitive automotive electronic component to the engine and
drive train vibrations while the vehicle travels rapidly down a rough road.
Transient Dynamic Analysis:
Transient dynamic analysis (sometimes called time history analysis) is a technique used to determine
the dynamic response of a structure under the action of any general time-dependent loads. Transient dynamic
analyses are used to determine the time-varying displacements, strains, stresses and forces in a structure as it
responds to any combination of static and time-varying loads while simultaneously considering the effects of
inertia or damping.
Transient dynamic analysis in ANSYS software can be broadly classified as one of two types:
Rigid dynamics: In an assembly, all parts are considered to be infinitely stiff, no mesh is required and a special
solver is used to drastically reduce the amount of computational resources required. The primary focus of a rigid
dynamics simulation is mechanism operation, part velocities and accelerations, as well as joint forces
encountered during the range of mechanism motion.
Flexible dynamics: Some or all parts of an assembly are meshed and considered flexible based on the materials
from which they are made. A flexible dynamics simulation typically is done after a rigid dynamics simulation is
used to verify the model setup. Flexible dynamics simulation can provide information about machine
performance, such as: • Will a machine or mechanism work adequately with light, more-flexible members, or
will stiffer but heavier members be required? • Will the forces transmitted through joints exceed the strength of
the materials being used? • At what rotational or translation speed will the mechanism experience plastic
deformation and begin to fail? • Will the mechanism‘s natural frequencies be excited and lead to instability? •
Will the repeated loading/unloading lead to fatigue and, if so, where?
Here in this project the transient analysis is performed as BUMP test where the structure is given
25g(g-gravitation acceleration) acceleration force for 6 milli seconds(as per JSS 55555 specifications) . This
acceleration force of 25g for 6 milli seconds signifies one BUMP, and the structure is subjected to 3 BUMPS
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per one second. The load of 25g acceleration force is normally distributed having a maximum amplitude of 25g
at 3 milli seconds. The response of the structure is then observed for further design considerations.
Random Vibration:
Random vibration is somewhat of a misnomer. If the generally accepted meaning of the term "random"
were applicable, it would not be possible to analyze a system subjected to "random" vibration. Furthermore, if
this term were considered in the context of having no specific pattern (i.e., haphazard), it would not be possible
to define a vibration environment, for the environment would vary in a totally unpredictable manner.
Fortunately, this is not the case. The majority of random processes fall in a special category termed stationary.
This means that the parameters by which random vibration is characterized do not change significantly when
analyzed statistically over a given period of time - the RMS amplitude is constant with time. For instance, the
vibration generated by a particular event, say, a missile launch, will be statistically similar whether the event is
measured today or six months from today. By implication, this also means that the vibration would be
statistically similar for all missiles of the same design. The assumption of a stationary process is essential in
both a technical and legal sense. As previously stated, it would not be possible for a designer to analyze a
system, nor for a user to test a system prior to installation in the field, if the vibration excitation were not
stationary. Consequently, it would not be possible to develop a legally binding specification. Any vibration is
described by the time history of motion, where the amplitude of the motion is expressed in terms of
displacement, velocity or acceleration. Sinusoidal vibration is the simplest motion, and can be fully described by
straightforward mathematical equations. Figure 1 shows the amplitude time plot of a sinusoidal vibration, and
indicates that sinusoidal vibration is cyclic and repetitive. In other words, if frequency and amplitude (or time
and amplitude) are defined, the motion can be predicted at any point in time.
Figure 1. Amplitude-Time History of Sinusoidal Vibration
A random vibration is one whose absolute value is not predictable at any point in time. As opposed to
sinusoidal vibration, there is no well defined periodicity - the amplitude at any point in time is not related to that
at any other point in time. Figure 2 shows the amplitude time history of a random vibration. The lack of
periodicity is apparent. A major difference between sinusoidal vibration and random vibration lies in the fact
that for the latter, numerous frequencies may be excited at the same time. Thus structural resonances of different
components can be excited simultaneously, the interaction of which could be vastly different from sinusoidal
vibration, wherein each resonance would be excited separately.
Figure 2. Amplitude-Time History of Random Vibration
Although the instantaneous amplitude of a random vibration cannot be expressed mathematically as an
exact function of time, it is possible to determine the probability of occurrence of a particular amplitude on a
statistical basis.
To characterize a stationary process, an ensemble of possible time histories must be obtained, wherein
the amplitude is measured over the frequency range of excitation. Thus, the three parameters of interest are:
frequency, time and amplitude. This information would provide the ability to analyze a random process in a
statistical sense. The characterization of random vibration typically results in a frequency spectrum of Power
Spectral Density (PSD) or Acceleration Spectral Density (ASD), which designates the mean square value of
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some magnitude passed by a filter, divided by the bandwidth of the filter. Thus, Power Spectral Density defines
the distribution of power over the frequency range of excitation.
The equipment designer is interested in avoiding mechanical failure and equipment malfunction. These
may be produced by different mechanisms, requiring different methods of corrective action. To the designer,
random vibration could be considered as either:
a) An infinite number of harmonic vibrations with unpredictable amplitude and phase relationships in the
frequency domain; or
b) The sum of an infinite number of infinitesimal shocks occurring randomly in the time domain.
In the first case, response at a particular frequency may be the primary concern. For example, when a
displacement sensitive device is excited at its natural frequency, relatively large displacements may result in
malfunction. In such a case, the malfunction might be corrected by reducing the amplitude of excitation at the
particular frequency of concern - the natural frequency of the device. This might be accomplished by inserting a
vibration isolator between the source of excitation and the device. Alternatively, displacement might be reduced
by adjusting the stiffness of the device, or by increasing damping at the natural frequency of the device.
If the random vibration is considered as an infinite number of infinitesimal shocks, the overall Grms
may result in a fatigue related structural failure of a component due to the intermittent shocks associated with
the random excitation. In this case, the problem might be corrected by reducing the overall Grms or by
increasing the strength of the component.
There is a relationship between these considerations. The nature of the equipment problem will affect
the type of corrective action to be investigated.
Characterization of Input Acceleration And Displacement
The simplest random excitation to analyze is a band limited white spectrum shown in Figure 4.
Figure 4. Band Limited White Spectrum
The overall input Grms is the square root of the area under the curve, i.e.,
This value could be used in Equation 1 to predict the probability of occurrence of instantaneous values
of acceleration for a random signal. For design purposes, Grms would generally be multiplied by three to
provide three sigma values.
In actual practice, it is not possible for a vibration shaker to generate the instantaneous drop off shown in Figure
4. Consequently, specifications generally show a roll off rate in terms of decibels per octave (dB/Oct.).
Figure 5 shows a possible input vibration spectra including roll-off rates.
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As in Figure 4, the overall Grms is the square root of the total area under the curve. However, since
most curves are plotted as straight lines on log-log paper, calculating the area under the sloped lines is more
complicated than for the region of constant PSD. To determine Grms for a spectrum with numerous break
points, G2 . for all areas are summed, and the square root of this summation results in overall Grms.
3.1 Model imported in to Ansys:
TABLE8: Geometry - Point Masses
Object Name mast1 'A' mast2 'B' shelter load 'C' jack1 'D' jack2 'E' jack3 'F' jack4 'G'
State Fully Defined
Scope
Scoping Method Geometry Selection
Applied By Remote Attachment
Geometry 1 Face 4 Faces 1 Face
Coordinate System Global Coordinate System
X Coordinate 1.078 m -0.183 m 0.4475 m -0.4815 m 1.4774 m
Y Coordinate 0.6 m 1.0431e-010 m -1.2e-002 m
Z Coordinate 0.55975 m 1.7 m 0.13 m
Location Defined
Definition
Mass 150. kg 1800. kg 50. kg 45. kg
Suppressed No
Behavior Deformable
Pinball Region All
1) MeshTABLE9: Mesh
Statistics
Nodes 59029
Elements 12761
Mesh Metric None
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B. Static Structural (H5)
TABLE10: Static Structural-Accelerations
Object Name Standard Earth Gravity
State Fully Defined
Scope
Geometry All Bodies
Definition
Coordinate System Global Coordinate System
X Component 0. m/s² (ramped)
Y Component -9.8066 m/s² (ramped)
Z Component 0. m/s² (ramped)
Suppressed No
Direction -Y Direction
TABLE11: Static Structural- Loads
Object Name Fixed Support
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Fixed Support
Suppressed No
Results:
TABLE12: Static Structural Solution-Results
Object Name Total Deformation Equivalent Stress
State Solved
Scope
Geometry All Bodies
Definition
Type Total Deformation Equivalent (von-Mises) Stress
Results
Minimum 0. m 444.2 Pa
Maximum 1.884e-003 m 5.9897e+008 Pa
Minimum Occurs On c- runner-1
Maximum Occurs On Assem3-1@2721 130 8 TOP PLATE-1
Minimum Value Over Time
Minimum 0. m 444.2 Pa
Maximum 0. m 444.2 Pa
Maximum Value Over Time
Minimum 1.884e-003 m 5.9897e+008 Pa
Maximum 1.884e-003 m 5.9897e+008 Pa
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Modal
TABLE13: Modal- Analysis Settings
Object Name Analysis Settings
State Fully Defined
Options
Max Modes to Find 6
The following bar chart indicates the frequency at each calculated mode.
FIGURE2: Modal -Solution
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TABLE14: Modal-Solution
Mode Frequency [Hz]
1. 4.1055
2. 5.8055
3. 7.4631
4. 9.3161
5. 11.024
6. 15.869
Mode 1:
Mode:2
Mode : 3
Mode : 4
Mode : 5
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Mode : 6
C. Transient
TABLE15: Transient Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Off
Define By Substeps
Number Of Substeps 1000.
Time Integration On
TABLE16: Transient - Accelerations
Object Name Acceleration
State Fully Defined
Scope
Geometry All Bodies
Definition
Define By Components
Coordinate System Global Coordinate System
X Component Tabular Data
Y Component Tabular Data
Z Component Tabular Data
Suppressed No
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FIGURE3: Transient (J5)- Acceleration
Solution
TABLE17: Transient Solution -Results
Object Name Total Deformation Equivalent Stress
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Total Deformation Equivalent (von-Mises) Stress
By Time
Display Time Last
Calculate Time
History
Yes
Identifier
Suppressed No
Results
Minimum 0. m 10343 Pa
Maximum 1.3171e-002 m 1.4614e+009 Pa
Minimum Occurs On c- runner-1
Maximum Occurs On
shelter iso wing front-1@2721 130 8 TOP PLATE front-
2
shelter iso wing front-2@2721 130 8 TOP PLATE front-
2
Minimum Value Over Time
Minimum 0. m 0. Pa
Maximum 0. m 15771 Pa
Maximum Value Over Time
Minimum 0. m 0. Pa
Maximum 2.3956e-002 m 4.7854e+009 Pa
Information
Time 1. s
Load Step 1
Substep 1000
Iteration Number 1000
Integration Point Results
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FIGURE4: Transient Solution- Total Deformation
FIGURE5: Transient Solution -Equivalent Stress
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Random Vibration
TABLE18: Random Vibration- Loads
Object Name PSD Acceleration
State Fully Defined
Scope
Boundary Condition Fixed Support
Definition
Load Data Tabular Data
Direction Y Axis
Suppressed No
FIGURE6: Random Vibration- PSD Acceleration
TABLE19: Random Vibration -PSD Acceleration
Frequency [Hz] Acceleration [(m/s²)²/Hz]
20.
2.e-002
50.
500. 1.e-003
Solution
TABLE20: Random Vibration Solution -Results
Object Name Directional Deformation Equivalent Stress
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Directional Deformation Equivalent Stress
Orientation Y Axis
Reference Relative to base motion
Scale Factor 3 Sigma
Probability 99.73 %
Coordinate System Solution Coordinate System
Suppressed No
Results
Minimum 0. m 157.34 Pa
Maximum 1.9107e-004 m 2.8622e+007 Pa
Minimum Occurs On c- runner-1 u bolt fixing assy- bigger-11@top plate-bigger-1
Maximum Occurs On shelter iso wing front-1@2721 130 8 TOP PLATE front-2 Assem3-1@2721 130 8 TOP PLATE-1
Minimum Value Over Time
Minimum 0. m 157.34 Pa
Maximum 0. m 157.34 Pa
Maximum Value Over Time
Minimum 1.9107e-004 m 2.8622e+007 Pa
Maximum 1.9107e-004 m 2.8622e+007 Pa
Information
Time 0. s
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Load Step 3
Substep 1
Iteration Number 1
Integration Point Results
Display Option Averaged
IV. Conclusion
From the above results it is observed that the stress levels are within acceptable limits and only in
transient bump analysis the stresses on the rear member are close to 1.5 factor of safety, which can be minimised
by either increasing the thickness of the member or adding the gusset plate at the joining cross members. Hence
the overall weight of the Flat levelling frame has come down from 660 Kg(conventional earlier design) to 450
Kg in the new modified design. Also there is a further scope to reduce the weight without compromising on the
strength by selecting carbon fibre composite material. Environment sustainability of carbon composite material
is much more superior to Mild steel. That is the carbon composite material shows more resistance to extreme
and harsh weather conditions comprising freezing temperatures, hot humid conditions, and salty environment
conditions.Validation of this environmental sustainability of carbon composite material can be done by
conducting Thermal shock analysis tests and salt spray tests in labs .
As the cost of this material is too high, this modification of replacing Mild Steel with Carbon
composite material needs to be carried out only under special cases where there is less regard to the cost and
much emphasis is placed on the weight reduction and strength enhancement.
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