International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

STRUCTURAL ANALYSIS OF HEAVY VEHICLE CHASSIS

USING COMPOSITE MATERIAL

D. Dhana Sudheer 1, D.Gopichand2,

1 Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.
2 Assistant professor , Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India.

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.

hicle).

This thesis deals with the design optimization and material suggestion for heavy vehicle chassis (container ve-

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.

*Corresponding Author:
D. Dhana Sudheer ,
Research Scholar, Department Of Mechanical Engineering,
Mother Theresa Institute of Technology(mist)
Khammam,India.
Published: Sep 24, 2014
Review Type: peer reviewed
Volume: I, Issue : III

Citation: D. Dhana Sudheer , Research Scholar

(2014) STRUCTURAL ANALYSIS OF HEAVY VEHICLE
CHASSIS USING COMPOSITE MATERIAL

Problem Description
Chassis is one of the major part in vehicle construction .Generally chassis is made of mild steel, these
type of chassis models are due to heavy weight vehicle is giving less mileage and also cost of the chassis
is high.
Rectification Methodology
AAs we know that weight of the chassis is the major problem in manufacturing,cost and mileage aspects.
In this thesis composite materials (FRP and CRPF)
will be analyzed for the replacement of traditional
materials 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 pressedsteel 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 combining the chassis frame and the body into a single structural element. In this grouping, the steel
body shell is reinforced with braces that make it
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International Journal of Research and Innovation (IJRI)

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 presence of heavier-gauge steel components in modern
separate frame designs also tends to limit intrusion
in accidents.
Introduction Of Chassis Frame:
AChassis is a French term and was initially used
to denote the frame parts or Basic Structure of the
vehicle. It is the back bone of the vehicle. A vehicle without body is called Chassis. The components
of the vehicle like Power plant, Transmission System, Axles, Wheels and tyre, Suspension, Controlling Systems like Braking, Steering etc., and also
electricalsystem parts are mounted on the Chassis
frame. It is the main mounting for all the components including the body. So it is also called as Carrying Unit.
Layout Of Chassis And Its Main Components:
The following main components of the Chassis are
1. Frame: it is made up of long two members called
side members riveted together with the help of number of cross members.
2. Engine or Power plant: It provides the source of
power
3. Clutch: It connects and disconnects the power
from the engine flywheel to the transmission system.
4. Gear Box
5. U Joint
6. Propeller Shaft
7. 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 oracceleration
4. To withstand the stresses caused due to the bad
road condition.
5. To withstand centrifugal force while cornering
Types Of Chassis Frames:
There are three types of frames
1. Conventional frame
2. Integral frame
3. Semi-integral frame
Design Goals
Chassis And Body Structure
The vehicle design starts up with conceptual studies to define size, number and location of un-driven
and drive axles, type of suspension, engine power,
transmission, tire size and axle reduction ratio, cab
size and auxiliary equipment. The selected configu-

ration has to be suitable for the considered transportation tasks and should match the existing production line. Either new vehicle type is generated
or a certain improvement over existing types has to
be achieved. Because of the fierce competition, and
advanced technology in engineering, manufacturing
and service and strenuous work is required to be
successful. Having defined the general configuration of a vehicle, let us now concentration the main
structural components. The most important function of the "backbone" is supporting and distributing the loads originating from.

payload including its vessels

axles with their fixtures

coupling device

drive train

truck cabin including top sleeper/windshield

inertia forces

forced deformation

special service functions like cab tilt mechanism, cargo handling

equipment
In addition to the primary structural functions, the
chassis has to incorporate accessories, optional and
special equipment like hydraulics, and electrical
wiring and piping systems.
Altogether, space is very limited and sometimes only
small cross section dimensions are usable for the
main structure.
Chassis Improvements

As standard, most chassis are designed to meet a

minimum set of requirements at a reasonable price
- as such, there are usually improvements that can be
made for vehicles that are going to be used for heavy
duty applications and racing.
Material Choice
If possible, one of the best ways to improve upon a
design is to ensure that the most suitable materials
are being used. Steel, for example, is available in various grades, and rebuilding a chassis using a higher
grade will give strength benefits - In drag racing, the
chassis of a competing vehicle must be built from a
minimum grade of metal in order to run in certain
classes.
Another good example of this is in tubing; the cheapest way to make tubing is to take a flat sheet of metal,
roll it into shape, and then weld the seam (such tubes
are referred to as electrical resistance welded, or ERW
- the picture on the left shows a machine used to do
this on an industrial scale). However, this seam can
be a weak point, and so extruding out a tube in one
(seamless) piece is preferable. Given that most of the
time, a space frame chassis is built for a specializedpurpose, seamless tubing will be used, this is more
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International Journal of Research and Innovation (IJRI)

relevant when building additional components such

as roll cages (below).

Model Of Honey Comb Chassis

Introduction To Creo 2.0

Creo 2.0 (pro/engineer) is the industrys standard 3D
mechanical design suit. It is the worlds leading CAD/
CAM /CAE software, gives a broad range of integrated solutions to cover all aspects of product design
and manufacturing. Much of its success can be attributed to its technology which spurs its customers to
more quickly and consistently innovate a new robust,
parametric, feature based model, because the Pro/E
technology is unmatched in this field, in all processes, in all countries, in all kind of companies along the
supply chains. Creo 2.0 (pro/enginer) is also the perfect solution for the manufacturing enterprise, with
associative applications, robust responsiveness and
web connectivity that make it the ideal flexible engineering solution to accelerate innovations. Creo 2.0
(pro/enginer) provides easy to use solution tailored
to the needs of small, medium sized enterprises as
well as large industrial corporations in all industries,
consumer goods, fabrications and assembly, electrical and electronics goods, automotive, aerospace etc.

The above image shows final model of honeycomb

chassis

The above image shows detail of honeycomb chassis

Model Of Existing Chassis

The above image shows 2d drafting

INTRODUCTION TO FEA

The above image shows side channel

The above image shows final model of existing

chassis

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 vibration systems. Shortly thereafter, a paper published
in 1956 by M. J. Turner, R. W. Clough, H. C. Martin, and L. J. Topp established a broader definition
of numerical analysis. The paper centered on the
"stiffness and deflection of complex structures".
By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries.
Since the rapid decline in the cost of computers
and the phenomenal increase in computing power,
FEA has been developed to an incredible precision.
Present day supercomputers are now able to produce accurate results for all kinds of parameters.
FEA consists of a computer model of a material or
design that is stressed and analyzed for specific
results. It is used in new product design, and existing product refinement. A company is able to
verify a proposed design will be able to perform to
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International Journal of Research and Innovation (IJRI)

the client's specifications prior to manufacturing

or construction. Modifying an existing product or
structure is utilized to qualify the product or structure for a new service condition. In case of structural failure, FEA may be used to help determine
the design modifications to meet the new condition.
Structural Analysis On Existing Design Of Chassis
Mild Steel

The above image shows von-misses stress

Fatigue Analysis On Existing Design Of Chassis

The above image is the imported model of chassis.

The above image shows safety factor

Structural Analysis On Modified Design Of
Chassis
Mild Steel

The above image showing the meshed modal.

The above image shows von-misses stress

The above image shows displacement

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International Journal of Research and Innovation (IJRI)

Structural Analysis On Honey Comb Design Of

Chassis

HONEY COMB
Mild Steel

E-Glass

S-Glass

Displacement

3.4035

9.9334

0.8634

Stress

39.594

40.381

40.154

Strain

0.000194

0.00057333

4.7511 e-5

Safety Factor

13.890

12.382

114.18

Biaxiality indication

0.9966

0.99516

0.9969

Alternative
Stress

79.188

80.763

80.309

Impact Anaylsis
material

existing

modified

Honey comb

displacement

8.390e

1.3107e

4.8526e5

stress

16.869

16.917

47.382

strain

0.000021605

0.000021617

0.0000546

The above image shows von-misses stress

Conclusion

Impact Analysis Of Existing Chassiss

This thesis works presents / works on structural optimization of chassis and implementation
of composite 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.

The above image shows equivalent stress

Results Tables
EXISTING
Mild Steel

E-Glass

S-Glass

Displacement

1.489

4.333

0.36

Stress

12.426

12.398

12.406

Strain

5.93E-5

0.000

1.4305 e-5

Safety Factor

44.262

40.329

369.57

Biaxiality indication

0.914

0.913

0.924

Alternative
Stress

24.853

24.795

24.812

MODIFIED
Mild Steel

E-Glass

S-Glass

Displacement

1.64

4.773

0.397

Stress

12.509

12.644

12.531

Strain

6.377 e-5

0.000190

1.5744 e-5

Safety Factor

43.968

544

365.89

Biaxiality indication

0.995

0.992

0.996

Alternative
Stress

25.017

25.289

First literature survey 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 levels (Alternating stress) using
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 structure weight is reduced up to 75% and quality is
improved by 87 % .So better to us above suggested
model & material.
S2-Glass chassis manufacturing is very easy
while compared with Mild steel.

25.206

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International Journal of Research and Innovation (IJRI)

Bibliography

Author

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3AMIT JOSHI(1)
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R.Deore3
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D. Dhana Sudheer 1,
Research Scholar, Department Of
Mechanical Engineering,
Mother Theresa Institute of Technology,
(mist) Khammam,India.

7.Haval Kamal Asker1, Thaker Salih Dawood1 and

Arkan Fawzi Said2
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D.Gopichand2,
Assistant professor , Department Of
Mechanical Engineering,
Mother Theresa Institute of Technology,
(mist) Khammam,India.

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