Virtual Simulation of Load Cases for Truck Chassis and its Analysis Using FEA

Abstract

Truck chassis forms the structural backbone of a heavy commercial vehicle. Whenthe truck travels along the road, the chassis is subjected to vibration induced by roadroughness and excitation by vibrating components mounted on it. The vibration ofthe chassis will also cause high stress concentrations at certain locations, fatigue ofthe structure, loosening of mechanical joints and creation of noise and vehicle dis-comfort. To solve these problems, study on the truck chassis dynamic characteristicsis thus essential.This thesis concentrates on analysis of vehicle using virtual prototyping approachwhich includes simulation of load cases for tractor-trailer combination. This helpsin to determine the loads acting on various components of tractor chassis, which areused as inputs to nite element model for stress analysis.Thesis includes, complete modeling of a full vehicle with its subsystems, front andrear suspensions with proper stiness, mass and inertia properties.Simulation of fth wheel coupling load case using MotionView and solution usingMotionSolve of Altair HyperWorks to determine kingpin load generated by couplingimpact, which is further used in FE model to perform stress analysis of chassis. Loadsare also determined using analytical method to validate results.Virtual test rig for simulation bump event, in which vehicle is subjected to sinusoidalroad excitations to determine acceleration at dierent points of a chassis, which isfurther used in FE model to perform inertia loading analysis of chassis.Finally Subsystem level analysis of exhaust system to compare various designs tocheck for modal acceptance criteria.