MECHANICAL ENGINEERING DESIGN 1 Report
Short Description
DESIGN SINGLE SEATER VEHICLE (CHASSIS)...
Description
FACULT FACULTY Y OF MECHANICAL MECHANI CAL ENGINEERING ENGINEER ING UNIVERSITY OF TECHNOLOGY MARA SHAH ALAM, SELANGOR
MEC532 MECHANICAL ENGINEERING DESIGN 1 FINAL REPORT
PROJECT TITLE: DESIGN & FABRICATE FABRICATE A SINGLE SEATER VEHICLE (CHASSIS)
TEAM LEADER SIGNATURE:
: AHMAD HASSAN B MUHD MUHAYYIDIN (20133411786)
TEAM MEMBER SIGNATURE:
: MOHAMAD HAZIM FAHMI BIN MOHD YAMIN (2012226818)
TEAM MEMBER SIGNATURE:
: MOHAMAD ZAID BIN MOHAMAD ZAILANI (2012241394)
TEAM MEMBER SIGNATURE:
: MUHAMAD SHAFI BIN SAUFI
TEAM MEMBER SIGNATURE:
: MOHAMAD FARIZ AIZAT BIN ABDAIN (2012223106)
TEAM MEMBER SIGNATURE:
: !U SITI FATIMAH AZZAHRA" BT !U MO!HTAR
(2012876726)
(2012#40029)
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PROJECT ADVISORS: Dr. AZIANTI ISMAIL
ABSTRACT This design project is the requirement for Part 5 students of F aculty of Mechanical ngineering! ach class "ere required to design a single seated #ehicle "hich comprises co mprises $ departments from each class "hich are chassis department% &od y"or' and safety department% &ra'ing department% steering department% po"ertrain department and suspension department! (e are from chassis department "ere required to &uild a strong and light chassis for our single seated #ehicle! Aspects of ergonomics% safety% ease of manufacture and relia&ility are incorporated into the design specifications! Analysis are conducted on all major components to optimi)ed strength and rigidity% impro#e #ehicle components and to reduce comple*ity and manufacturing costs! +, models ha#e &een made for analysis purpose &y using CAT-A CAT-A soft"are and analysis has &een made! +, assem&ly a ssem&ly models of the single seated #ehicle are d esigned for understanding purpose!
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AC./0(1,2M/T Apart from the effort of us% this design project "as done successfully &ecause of the encouragement and guidelines from many others! (e "ould li'e to ta'e this #alua&le opportunity to e*press our gratitude to the people "ho ha#e &een a &ig help to us during completion of this project! First and foremost% (e "ould li'e to than' our &elo#ed lecturer ,r A)ianti -smail % "ho has supported us throughout this project "ith his patience and 'no"ledge! 2uidance &y him physically and mentally is #ery #alua&le! 3e inspired us greatly to "or' in this project! 3is 3is "illingness to moti#ate us contri&uted tremendously to our project! All these are the #ital factors "hich dri#e us till the end! Secondly% "e "ould li'e to offer our sincerest gratitude to mem&ers from other department "ho pro#ide us useful opinions and suggestions along the implementation of this project! Their support made us a&le to complete this project! They They are al"ays &y our side "ithout tired and fail "hen they are needed! Beneficial ad#ices are o&tained from them! 0n the other hand% "e "ould li'e to ta'e this opportunity to than' our family mem&ers for supporting and encouraging us during d uring the completion of this project! 0ur deepest gratitude from the &ottom of our heart for the support% encouragement and inspirations "e o&tained during this project! 1ast &ut not least% "e "ould li'e to than' e#ery&ody "ho "as important to the successful reali)ation of this design project as "ell as e*pressing our apolog y that "e could not mention personally one &y one!
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1! ORGANI"ATION CHART
GROUP LEADER
AHMAD HASSAN
HEAD OF PRODUCTION MOHAMAD FARIZ AIZAT PRODUCTION
ASSISTANT
HEAD OF DESIGNER MUHAMMAD SHAFIQ ASSISTANT ASSISTANT DESIGNER DESI GNER
SECRETARY
KU SITI FATIMAH ’
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11 INTRODUCTION
Chassis is the most important part of fa&ricating of single seated #ehicle! -ts department plays a #ery important role &ecause it is much related to other components of the #ehicle! The change in dimension and design of chassis "ill affect the designation of other component of the #ehicle! Chassis consists of an internal frame"or' that supports a man4made o&ject in its construction and use! Chassis ser#es as an aero de#ice% &oth &y directing air &ut also &y supporting the deflection of other aero components! The chassis also act as the dri#ers center of confidence! -f the dri#er does not feel safe% either due to "ea' impact )ones or fle*i suspension feed&ac' % he "ill not go fast! Argua&ly more importantly% he may &e injured &y an unsafe chassis! Finally% the dri#er must &e entirely comforta&le! A good chassis must ha#e follo"ing characteristics6 •
Be structurally sound in e#ery "ay o#er the e*pected life of the #ehicle and &eyond! This
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means nothing "ill e#er &rea' under normal conditions! Maintain the suspension mounting locations so that handling is safe and consistent under
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high cornering and &ump loads! Support the &ody panels p anels and other passenger components so that e#erything feels solid
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and has a long% relia&le life! Protect the dri#er from e*ternal injuries! For this project% "e are going to &uild a single seated #ehicle &ased on SA car formula! All specification "ill &e &ased on SA car formula!
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PR07CT P1A//-/2 2A/TT C3ART
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2! LITERATURE REVIE#
8!9!9 Studies on Chassis ,esign Functions of chassis design 9! 8! +! :! 5!
To carry load load of the the passengers passengers or goods carried carried in the &ody! &ody! To support support the load load of the the &ody% &ody% engine% engine% gear and others others system! system! To "ithstand "ithstand the forces forces caused caused due to to the sudden sudden ra'ing or or acceleration acceleration!! To "ithstand "ithstand stress stresses es caused caused due to the &ad road road condition condition!! The "ithstand "ithstand centrifugal centrifugal force "hile cornering! cornering!
Types Types of chassis frames There are se#eral types of chassis frames that ha#e & een studying such as6 9! Con# Con#en enti tion onal al fra frame me 8! -nt -ntegra egrall fr frame ame +! Semi4 Semi4in inte tegra grall fram framee Con#entional frame -t has long side mem&ers and 5 to $ cross mem&ers joined together "ith the help of ri#ets and &olts! The frame sections used generally ha#e + sections! The first section is channel section "hich has good resistance to &ending! & ending! Second is the ta&ular section "hich supposedly has good resistance to torsion! (hereas the &o* section may has good resistance to &oth &ending and torsion!
Figure 96 Con#entional frames -ntegral frame This type of frame is used no"adays in most of the cars! There is no frame and all the assem&ly units are attached to the &od y! All the functions of the frame carried out &y the 7
&ody itself! ,ue to elimination of long frame it is cheaper and due to less "eight and most economical too! The disad#antage is difficulty in repairing of the chassis!
Figure 86 -ntegral frame Semi4integral frame -n some #ehicles% half frame is fi*ed in the front end on "hich engine gear &o* and front suspension is mounted! -t has the ad#antage "hen the #ehicle is met "ith accident acc ident the front frame can &e ta'en easily to replace the damaged chassis frame! This type of frame is used in F-AT F-AT cars and some of the uropean and American cars!
Figure +6 Semi integral frame
Frame 1oading 2enerally there are #arious loads acting on the frame "hich is6 9! Short durati duration on load ; acted on frame "hile "hile crossin crossing g a &ro'en &ro'en patch! 8! Momentary Momentary duratio duration n load ; acted acted on frame frame "hile "hile ta'ing ta'ing a cur#e! 8
+! :! 5! $!
-mpact loads ; acted acted on frame frame due to collisi collision on of the the #ehicle! #ehicle! -nertia -nertia loads loads ; may may e*perience e*perience this load "hile "hile applyi applying ng &ra'es! &ra'es! Static Static inertia inertia ; it is the the loads due due to chassis chassis parts parts at static static condition! condition! 0#er loads loads ; happened "hen the the load is &eyond &eyond design design capacity capacity!!
8!9!8 Studies on Materials for Chassis -n this material selection part% "e ha#e to consider many properties of material &efore ma'ing the choice! There se#eral type of material that can &e compared such as steel% aluminum and an d titanium!
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S$%%
The properties that need to &e considered6 9! Strength 8! Toughness ess +! ,uctility :! (e (elda&ility lda&ility ; determined &y & y the chemical content c ontent of the alloy% "hich is go#erned &y limits in the product standard! 5! ,ura&ility ; depends on the particular alloy type
Figure :6 Schematic Stress Strain diagram for steel
Figure 56 Stress Strain &eha#ior for steel
A'*' P+-%+$%.
(eight Strength 1inear e*pansion Machining
D%./+-$* ! to $!5 mm are used in 2MA(! The si)e depends on the thic'ness of the parts &eing joined and the desire deposition rate! 2ases are used for shielding include inert gases such as argon and helium% and acti#e gases such as car&on dio*ide! Selection 12
of gases depends on the metal &eing "elded% as "ell as other factors! -nert gases are used for "elding aluminum alloys and stainless steels% "hile C0 8 are commonly used for "elding lo" and medium car&on steels! 2as metal arc "elding 2MA(D% sometimes referred to &y its su&type metal inert gas M-2D "elding or acti#e gas MA2D "elding! -t is a semi4automatic or automatic arc "elding process! The "elding process operates &y using the direct current po"er source usually "ith the "ire electrode positi#e% is most commonly used "ith 2MA( &ut constant current system% as "ell as alternating current% can &e used! This is 'no"n as re#erse polarity "here the straight polarity is used &ecause of the poor transfer of molten metal from the "ire electrode to the "or'piece! There are four primary methods of metal transfer in 2MA(% called glo&ular% short4 circulating% spray% and pulsed4spray% each of "hich has distinct properties and corresponding ad#antages and limitations!
Figure $6 2as metal arc "elding 8!9 ,esign requirement
9! 0nly struct structural ural space space frame frame chassis chassis type type are allo"ed allo"ed no monocoque monocoque type type D 8! The chassis chassis must &e made made from structura structurall steel or structur structural al steel alloy alloy tu&ing tu&ing meeting the the -S0 :@: classifications and the -S0 :@:@ designations! Alloy steel ha#ing at least one alloy element the mass content of "hich G 5H are for&idden! +! The #ehicle #ehicle chassis chassis must must &e equipped equipped "ith an effec effecti#e ti#e roll roll &ar that e*tends 5>mm around the dri#ers helmet and also e*tends e* tends in "idth &eyond the dri#ers shoulders "hen seated in normal dri#ing position! 13
:! Any roll &ar &ar must &e capa&le capa&le of "ithstandi "ithstanding ng a static static load of =>> / appro*! appro*!=>'g =>'g D applied in #ertical% hori)ontal% or perpendicular d irection% "ithout deforming 5! The dri#er dri#er must ha#e adequate adequate #isi&ilit #isi&ility y to the front and and sides of the the car! (ith (ith the dri#er dri#er seated in a normal dri#ing position heshe must ha#e a minimum field of #ision of 8>> degrees a minimum 9>> degrees to either e ither side of the dri#erD! $! The required required #isi&ilit #isi&ility y may &e o&tained o&tained &y the the dri#er turning turning hisher hisher head andor andor use of mirrors! =! The side impact impact structu structure re for tu&e tu&e frame frame cars must must &e comprised comprised of at least least three three +D tu&ular mem&er located on each side of the dri#er "hile seated in the normal nor mal dri#ing position! ! All necessary necessary analysis analysis and and calculation calculation e!g! e!g! front and side side impact analysi analysis% s% roll &ar analysis% C!0!2 location% structural strength ana lysis &endingtorsionD% material use analysis% joint method analysis anal ysis &olt"eldingother joint methodD
3! PHASE 1: CONCEPTUAL DESIGN
+!9 0&ject 0&j ecti#es i#es Stri#ing to achie#e the major aims% the chassis department focuses on 9! To perform perform aestheti aestheticc chassis design design "hile fulfill fulfilling ing specificati specification on stated &y faculty! faculty! 8! To perform perform a successful successful analysis analysis of chassis chassis of a single single seated #ehicle #ehicle "hile "hile incorporated incorporated "ith all department! +! To produce a complete complete relia&le relia&le of +, model model chassis chassis design design of a single seated seated #ehicle #ehicle "ith assist of CAT-A soft"are! :! To design a chassis chassis that that "ill "ill &e easily easily adapta&le adapta&le and and adjusta&l adjusta&le! e! +!8 Pro&lem Statement Stateme nt
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9! The chassis chassis must must &e equipped equipped "ith an effect effecti#e i#e roll roll &ar that e*tends e*tends 5>mm 5>mm around around the dri#erIs helmet! 8! The roll &ar must capa&le capa&le to to "ithstand "ithstand =>>/ applied applied in in a #ertical% #ertical% hori)ontal hori)ontal or or perpendicular direction "ithout deforming! +! The minimum minimum field field of #ision #ision of dri#er dri#er must 9>> 9>> degrees degrees to either either side of of the dri#er dri#er!! :! The side impact impact structu structure re must &e &e comprised comprised at least least + tu&ular tu&ular mem&ers mem&ers located located on each side of the dri#er!
+!8 Product ,esign Specification
PRODUCT MASS
: Cha! "#$ F#$%&'a S(&)*+( Ca$ : A,,$#-!%a(* 40./
SIZE 1050%%
: *+/(h 2090%% !)(h 510%% h*!/h(
TIMESCALE
: 18 **. "$#% "$#% !+!(!a' ,ha* (# %a+&"a(&$*$ %a+&"a(&$*$
COST
: RM 17670
QUANTITY
: 51 ,!**
SAFETY
: D*!/+*) (# h#') #''!!#+ !%,a( !+* (h* "$a%* +#( )a%a/* a)' !+ a* #" a!)*+(
COMPETITION
: a$!#& ha! "$#% #(h*$ FKM /$#&,
MAINTAINANCE
: *')*) ;#!+( +**) (# * !+,*(*) 15
MANUFACTURING FACILITY : TI< *')!+/ %ah!+* /$!+)*$ &( #= %ah!+* h)$a&'! *+)!+/ %ah!+* INSTALLATION *')!+/
: A'' #" (h* ,!** !'' * ;#!+ ,#( a+) TI<
MATERIALS
: M!') S(**'
+!+ Physical ,ecomposition
Figure =6 Physical decomposition of chassis 16
Physically% chassis does not ha#e physical component to dissect! Therefore the chassis is di#ided into : su&components "hich are front component% centralcoc'pit component% rear component% and &ody"or' component! The front component "ill &e design to install suspension system% &ra'ing system% and steering system! (hile at the central of chassis it is "here the &ra'e pedal and the throttle pedal "ill &e located! As for rear component% "e "ill design appropriate section for po"er train installation% &ra'ing and suspension system! The "hole &ody"or' of the chassis design must ha#e cooperation "ith &ody"or' department depa rtment in order to achie#e the aesthetic design of car &ody!
+!: Functional ,ecomposition
Figure 6 Functional decomposition of chassis The chassis carrying fe" functions such as pro#ide safety and relia&ility% acquire acquire ergonomic design% aerodynamic% high dura&ility% dura&ility% high sta&ility! Chassis must ha#e strong and 17
rigid frame in order to pro#ide safety for dri#er during impact! -t must &e relia&le to a&sor& the impact so that any injury on the dri#er can &e a#oided! -t is important for the chassis to &e in ergonomic shape so tha t the chassis can ha#e high aesthetic #alue to attract people plus pro#iding co mfort and user friendly in "hich the dri#er should &e a&le to easily get ge t into and out of the ca r! There There also must not ha#e any an y sharp edges from the internal space to ensure the dri#er safety! The aerodynamic of the chassis "ill play an important role for &ody"or' to design the car &odyJ a good design of chassis "ill help in increase #elocity of the car! The chassis frame must &e dura&le as it is the main component "here other systems "ill &e attached! -t must a&le to "ithstand normal stress and shear stress! stress! 0ther than that% the chassis is design to &e sta&le at all dri#ing condition co ndition for e*ample during static% cornering% high speed condition% and &ra'ing condition! -t must also a&le to "ithstand the #i&ration of the car to protect internal system &rea'do"n! +!5 Morphological Chart
MATERI AL ST>>
BAR SHAPE
FRONT
COCKPIT
REAR
R>CTAN< >
AUMINIU M
D*!/+ 1
ROUND
D*!/+ 2 D*!/+ 3
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TITANIUM TITANIUM OA D*!/+ 4
AO?
Figure @6 Morphological chart Morphological chart is a pictorial approach to illustrate a d esignerIs ideas and help to choose the &est design to meet "ith the function requirement! Multiple designs for each of the function are first listed in form of the ta&le! Basic approach to create the chart is &y listing the function requirement on the left side of the ta&le% "hile on the right side% different mechanisms "hich can &e used to perform the functions listed are dra"n! A morphological chart can &e a &ig and comple* chart &ased on the designerIs idea% function decomposition of each part and also different mechanisms gathered from their literature re#ie" itself! The idea generation is finally accomplished &y creating single systems from different mechanisms illustrated in the morphological chart! 0ur chassis department had conducted a lot of research and re#ie" from #arious resources including the chassis designed &y the student &efore! Throughout &rainstorming% "e learn that chassis design is &asically can &e decomposes to three major function "hich is coc'pit% front and rear frame! (e understood understood that coc'pit is the most crucial area as it is "here the dri#er is placed! So% it has to &e & e &uilt "ith the sense that it can &ear & ear the impact front all side of the dri#er ho"e#er it is also important to ma'e sure the coc'pit area is effecti#e enough that it does not significantly affect the o#erall "eight and si)e of the ca r! The The chart a&o#e sho"s : ideas of coc'pit design!
The front s'eleton of the car is "here the other part of the car is mounted! mounted! -t is interconnected "ith the suspension% &ra'ing and steering system! Front frame is also "here the 19
&ra'ing and gas pedals are located! Based on this fact% it is necessary for the frame"or' to &e "ell concomitant "ith the partIs joining point "ithout neglecting the dri#erIs space to freely handle the pedals! -t is also important to guarantee gu arantee that the dri#er is fully protected from the front impact and a&sor& the impact at particular speed! 3o"e#er the attenuator design is charged un der &ody"or' department and is not &eing included here! The #ery last part is the rear frame "hich can &e considered as engine compartment!
+!$ Pugh Concept Selection Method
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Figure 9>6 Pugh Concept Selection Method
Pugh concept selection method is a method for concept selection using a scoring matri* called the Pugh Matri*! -t is implemented &y esta&lishing an e#aluation team% and setting up a matri* of e#aluation criteria #ersus alternati#e em&odiments! The scoring matri* usually associated "ith the LF, method and is a form of prioriti)ation matri*! These get con#erted into scores and com&ined in the matri* to yield scores for each option! •
ffecti#e for comparing alternati#e concepts
•
Scores concepts relati#e to one another
•
-terati#e e#aluation method
Comparison of the scores generated gi#es insight into the &est alternati#es! Based on the figure a&o#e% the concept 9 "hich is the design 9 attains the highest score "ith "eighted of :8! This is &ecause in the design 9% the &ar shape selected is rectangle cross section shape! This shape can &e easily found in the mar'et in cheaper price! The front s'eleton chosen is the most practical shape for the chassis "ith enough support &eam and easy to assem&le! The coc'pit of design 9 has + tu&ular mem&ers as required from specification and the roll &ar is high% and easy to fa&ricate! (hereas at the rear s'eleton% the design 9 compartment engine is &etter compare to other type in the morphological chart! chart! The +rd design of rear s'eleton ha#e smaller &ase! This "ill effect in terms of sta&ility of the chassis! -t pro#ides large space yet less comple*ity of geometry shape! -n terms of scoring in the Pugh method the design 9 may fit all others criteria e*cept for the "eight is the minus point due to fe" support that need to &e added to "ithstand load! Therefore% design 9 is c hosen &ased on the high #alue in criteria of dura&ility% ergonomic ergonomic shape% sta&ility% sta&ility% safety% aesthetic #alue% aerodynamics &ut still in the lo"est cost! For concept 8 there are t"o minus point on t"o criteria "hich is cost and sta&ility! This result in total "eighted of 8>! As for concept +% it o&tains the least total "eighted of 48 due to many minus point in four criteria "hich is the cost% sta&ility% sta&ility% ergonomic and aerodynamic! The 21
cost is high due to the using u sing of -4&ar cross section! This -4&ar is #ery e*pensi#e same as in concept 8! The coc'pit s'eleton is "ider thus not good in terms of aerodynamic! aerod ynamic!
:!> P3AS 86 MB0,-M/T ,S-2/
:!9 Product Architecture
All structures are made from rectangular cross4sectional shape!
S&,*+!#+ S(**$!+/
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Rear
S&,*+!#+
#*$ ($a!+
Fr!t
Overall
@$a.!+/ (*%
@$a.!+/ (*%
@#)#$. a+) a"*(
The product architecture is the arrangement of physical elements to carry out its required function! Chassis play an important role to all others department function! Chassis "ill pro#ide space to assem&le systems! The front s'eleton is the position "here the suspension system "ill &e installing! From the suspension system the &ra'ing system system "ill attach its &ra'e disc and others component! -n the same time% the steering department "ill attach its 'nuc'les% and steering system of rac' and pinion! 0n the rear s'eleton% the chassis is design to fit the si)e of engine used that had h ad &een decided &y po"er train department and an d also for the &ac' tires from suspension department and &ra'ing department since &ra'e system is on the all four tires! For the o#erall chassis% the
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&ody"or' and safety "ill design the s'in of the &ody and also the attenuator% dri#er seat and others important safety component of the car! The chassis is ,esign for 3uman Factor in "hich the determination of the si)e of the coc'pit is &y measuring the actual dri#er si)e! Besides% "e also added up some tolerances to the dimension of the dri#er si)e so that the dri#er can easily get into or out from the car! -n the inside of the frame"or'% the &ody"or' department ma y also attach safety padding at the side to pre#ent injury in case of high impact and pro#ide comfort for dri#er!
:!8 Configuration ,esign The designation of chassis is &ased on 3uman Factor thus measuring the dri#er si)e is at follo"s!
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Figure 996 ,ri#er dimension 0ur dri#er "ill &e seated at that particular position and his shoulder "idth are also measured! After added fe" tolerances and discussing "ith other department of system% the final dimension is decided!
Figure 986 Base dimension of chassis
:!+ Product ,e#elopment
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Figure 9+6 Flo" chart of the product de#elopment
,S-2/ 9
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Figure 9:6 -sometric #ie" of design 9
The diagram sho"s the first design that "e made! The first design does not ha#e enough support therefore some &eam need to &e & e added! All the &lue highlighted lines are the &eams that need to &e impro#ed! 3ere% "e impro#e on the &ac' roll &ar% the &ase of dri#er seat% the side impact tu&ular mem&er% and the support &et"een the roll &ar and the engine cage!
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,S-2/ 8
Figure 956 -sometric #ie" of design 8
From the figure a&o#e% all the modification in design 9 has &een done! 3o"e#er% on the front roll &ar the height need to &e increase to pro#ide space for steering department to place their steering% and the shaft needed for the system! As the front roll &ar is increase the &ac' roll &ar must also increase in order to fulfill requirement requirement &y faculty that the effecti#e roll &ar must e*tend 5>mm around the dri#er helmet!
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,S-2/ +
Figure 9$6 -sometric #ie" of ,esign +
As seen in the figure a&o#e for the +rd design% the impro#ement is less! The &lue lines are only on the &ase of the dri#er seat! (e decided to change the dri#er seat support to ease the fa&rication process &y according to ,esign for Assem&ly ,FAD! ,FAD! Before the modification% the inclined &ar "ill &e "elded on the sharp corner in "hich% precision to cut cu t the &ar according to the angle is difficult due to limited of machinery in the "or'shop! -f the angle of the &ar is not no t precise the "eld of the joint "ill not enough to "ithstand load thus the structure "ill "ill fail!
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,S-2/ :
Figure 9=6 -sometric #ie" of design : The figure a&o#e sho"s the final impro#ement that "e made! T"o long &eam is added on the &ase of the chassis to support the po"er p o"er engine at the rear! Front chassis "ill support the steering% &ra'ing and suspension system! 0n the front side% fe" #ertical &eams is added to ena&le shaft placement of suspension and the same time a#oid force deformation acting from #ertical! Supports are also added at the rear to help in supporting the &ac' roll &ar and the engine cage!
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F-/A1 ,S-2/
Figure 96 Final ,esign The figure sho"s our complete of final design! After "ent through a num&er of re#olution% modification of support and cooperation "ith other dep artment% "e &elie#e this is the most relia&le% sta&le and fulfill others functional department!
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:!: Parametric ,esign Figure 9@6 Parametric ,esign 9
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Top #ie"
Front #ie"
33
Side #ie" -sometric #ie"
Figure 8>6 Parametric ,esign 8
34
Top #ie"
Side #ie"
35
Front #ie" -sometric #ie" Figure 896 Parametric ,esign +
36
Top #ie"
Side #ie"
37
Front #ie"
-sometric #ie" Figure 886 Parametric ,esign :
38
Top #ie"
Side #ie"
39
Front #ie"
-sometric #ie"
:!5 Analysis of Chassis Analysis on the chassis must &e done in order to identify the strength of the structure in #arious conditions such as during static condition% mo#ing at particular #elocity% impact impact
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condition and many more! ,uring each condition% the strength of material is differing from each other! The strength of the structure can &e determined &y & y using CAT-A CAT-A or A/SS! A/SS! By using CAT-A% CAT-A% the analysis is carried out through nu merical technique of finite element method FMD! FM encompasses methods for connecting many simple element equations o#er many small su&domains% named finite elements! -n order to appro*imate a more comple* equation o#er a larger domain "here using the manual calculation is impossi&le% these finite element method is applied! Therefore to ease the determination of stress acting on chassis frame% this method can &e used such that
9> /m8% the >/ acting in static condition! con dition! As "e run the analysis% the $mm from the original position! The orange area% the displacement occur is 5!:$mm! (heareas on the yello" area% the displacement is :!5mm from its original position! -f "e can see the displacement of is happen on the other side of the point loading% it is not impossi&le &ecause the dra"ing might ha#e some e rror in "hich the length is not perfectly same on &oth side! As a conclusion% the test is successful since the induc ed stress is less than the yield strength of material plus #ery small displacement occurs on the cha ssis structure! The structure is safe enough and suita&le for installation of suspension% &ra'ing% and steering system at the front s'eleton due to sta&ility of the front chassis from torsional moment acted upo n it!
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:! Clash Clash Tor Torsio sion n Frontal Frontal Momen Momentt Tes Testt
Figure 8@6 /m8 yield strength of steelD! The
chassis pass the mounting analysis! -t a&le to "ithstand all forces from systems acted on it! The ma*imum translational displacement in the figure +5 is @$!mm from its original position! -t is decreases gradually do"n"ard the scale of the colour field pattern until the displacement is )ero and the most &ottom of &lue! The red area is not as much as pre#ious test therefore it una&le to &e seen clearly! 3o"e#er the analysis anal ysis pass successfully due to
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