Static Load Analysis of Tata Super Ace Chassis and its Verification Using Solid Mechanics
STATIC LOAD ANALYSIS OF TATA SUPER ACE CHASSIS AND ITS
VERIFICATION USING SOLID MECHANICS
1
MANPREET SINGH BAJWA, 2YATIN RATURI, 3AMIT JOSHI
Mechanical Engineering Department G.B.Pant Engineering College, Pauri Garhwal, Uttarakhand, India
Abstract Automotive chassis can be considered as the backbone of any vehicle. Chassis is tasked at holding all the
essential components of the vehicle like engine, suspension, gearbox, braking system, propeller shaft, differential etc. To
sustain various loads under different working conditions it should be robust in design. Moreover chassis should be stiff and
strong enough to resist severe twisting and bending moments to which it is subjected to. This paper presents the static load
analysis (excluding damping and inertia effects ) of the chassis of TATA super ace using ansys workbench and its
verification using solid mechanics.
Keywords-FEM, CAD, G.V.W. , CATIA.
I.
INTRODUCTION
III.
Chassis usually denotes the basic frame that
decides the overall shape of the vehicle. It is aimed at
holding important components of the vehicle. Here
the chassis of TATA super ace is of ladder frame type
which has two side members or longitudinal members
of C- cross section and five transverse members called
as cross members of box cross section. The chassis
has been modelled in CATIA V5R18 using the most
of the actual dimensions. FEM analysis was done
using ansys 14 workbench.
II.
FEM ANALYSIS OF CHASSIS
For carrying out the FE analysis of the frame the
CAD model is prepared in CATIA and then the
analysis is done in ansys workbench. CAD model is
prepared using following dimensions:-
BASIC CALCULATION
Model:- tata super ace
Length of vehicle = 4340 mm
Width of vehicle = 1565 mm
Height of vehicle = 1858 mm
Wheelbase = 2380 mm
Track width = 1320 mm
Material of chassis = structural steel
Youngs modulus = 2 e+5
Poissons ratio = 0.3
Length of chassis = 4201 mm
Width of chassis = 808 mm
Dimensions of side bar = 100mm x 36mm x 5 mm
Dimensions of cross bar = 90 mm x 90 mm
Gross vehicle weight (G.V.W) = 2180 kg
Kerbweight = 1180 kg
Figure 1 Dimensions of cross sections
The above load (G.V.W) is applied in the form of
pressure.
Hence the total area of application of load as
calculated from chassis dimensions = 1182600 mm2.
Total load to be applied = 2150 x 9.81
= 21091.5 N
Pressure to be applied = 21091.5/1182600
= 0.017834 MPa.
Figure 2 CAD model of chassis
IRAJ International Conference, Delhi Chapter- 26th May 2013, ISBN: 978-81-927147-5-2
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Static Load Analysis of Tata Super Ace Chassis and its Verification Using Solid Mechanics
IV.
mises stress magnitude is 146.37 MPa. Also the
magnitude of total deformation is 1.6471 mm.
MESHING
Meshing is done using the auto mesh mode of ansys
workbench. The mesh model has 8112 elements and
20998 nodes.
Figure 5 Stress intensity
Figure 3 Meshed model of chassis
V.
LOAD APPLICATIONS AND
BOUNDARY CONDITIONS
Load is applied in the form of pressure of magnitude
0.017834 MPa. There are two boundary conditions
which includes fixing the front and the rear axle.
Figure 6 Von Mises stress
Figure 4 Fixed support and pressure application
VI.
RESULTS
The maximum stress intensity of magnitude 149.51
MPa is found to be in close proximity of rear axle at
the joint of side member and cross member. The von
Figure 7 Close view of maximum stress
IRAJ International Conference, Delhi Chapter- 26th May 2013, ISBN: 978-81-927147-5-2
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Static Load Analysis of Tata Super Ace Chassis and its Verification Using Solid Mechanics
BENDING MOMENTS:BMB (at B) =
- {5.0206 x (1085)2 }/2
=
-2955187.91 N-mm
BMA (at A) = - {5.0206 x (3446)2}/2 + 12019.76 x
2361
= -1430948.275 N-mm
Hence the maximum bending moments occurs at B.
MOMENT OF INERTIAS:M.O.I. of side members (I1) = 36 x (100)3 /12
- 31 x (90)3 /12
= 1116750 mm 4
M.O.I. of cross members (I2) = 90 x (90)3 /12
-80 x (80)3 /12
= 2054166 mm4
Total M.O.I (I) = 1116750 x 2 + 2054166 x 5
= 12504333.33 mm4
Using the bending equation,
Figure 8 Total deformation
VII.
VARIFICATION OF RESULTS USING
SOLID MECHANICS
M/I=b/y,
Verification of software results can be done by
considering the chassis as an overhanging beam
carrying a uniformly distributed load (U.D.L).
(1)
b = My/I1
= 2955187.91 x 50/ 1116750
= 132.312 MPa
Uniformly distributed load = total load/length of
chassis
Deflection of the chassis can be calculated using the
empirical formula (ref to the structural analysis of
ladder chassis frame ISSN 2232-2587)
=21091.5/4201 =5.0209 N/mm
Y = wL(b-L)[ L(b-L)+b2 2(c2+a2) -2b-1{c2 L + a2 (bL)} ]
24 EI= 2.0803 mm
Hence the stress and the deflection calculated are
close to software values i.e 149.51 MPa and 1.6471
mm. the slight deviations in the values are may be
because software not able to reproduce actual
conditions and simplification of the chassis model.
CONCLUSION
Figure 7 chassis as an overhanging beam
Calculating the reactions RA and RB :Here
RA + RB = 21091.5 N
Finally the design, static analysis and its verification
using solid mechanics has been successfully
accomplished. The work not only provides an insight
into the design and analysis of the chassis but also
pinpoints the critically stressed points where the
design can be modified for improving the chassis.
Taking the moment about A,
RB x 2361 = 17300.98 x 1723 - 3790.55 x 377.5
ACKNOWLEDGMENT
RB = 12019.76 N
I am very thankful to my project guide Amit Joshi,
Assistant professor, Mechanical Engineering Deptt. ,
G.B. Pant Engineering College, Pauri Garhwal. for
RA = 9071.74 N
IRAJ International Conference, Delhi Chapter- 26th May 2013, ISBN: 978-81-927147-5-2
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Static Load Analysis of Tata Super Ace Chassis and its Verification Using Solid Mechanics
his continuous support and encouragement in
completing this work.
[3]
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IRAJ International Conference, Delhi Chapter- 26th May 2013, ISBN: 978-81-927147-5-2
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