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Structural Modellingof a Monocoque Closed Integral Sedan Car Body

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Structural Modellingof a Monocoque Closed Integral Sedan Car Body Published by : International Journal of Engineering Research & Technology (IJERT) http://www.ijert.org ISSN: 2278-0181 Vol. 7 Issue 09, September-2018 Structural Modelling of a Monocoque Closed Integral Sedan Car Body Ahmed Khtab Mohamed Abd El-Moneim Automotive Department Machine Design & Production Department MTC MTC Cairo, Egypt Cairo, Egypt Metwally Mohamed Automotive Department MTC Cairo, Egypt Abstract—This The car body structure is a highly redundant The- Integral (monocoque) structure is that type of structure structure with more than one load path and the sharing of the where the all bodywork, except the door and hatches, are load load is a function of the component relative stiffness. In static carrying elements, so obtaining lighter integral body/chassis stress analysis, only the loads that cause elastic strains and structure with less Hysteresis effect in the unloading curve than stresses in the structure are studied in such a way that there is no the ladder frame due to slippage between the body & chassis at yielding of the material or joint failure . Practical experience the mounting points obtaining a more lighter and stronger car, suggests that a vehicle structure which is strong enough to endure as shown in Fig 1 [4] the maximum dynamic loads, which occur sporadically, will also have sufficient resistance against repeated dynamic forces at less Modeling process, which is considered as the major part in than their average value (fatigue loading). Then the key factor in structural stress analysis, is obtained by representing the the design analysis process is the determination of The Dynamic physical car body as an idealized structural model valid for Load Coefficient’ which can be used in the static analysis. [1] applications of different suitable structural analysis theories to ensure the continuity for the load path through the structure, the The structural stress analysis of the car body is carried out by the integrity of the structure, and that the structure is capable of discussion of: transferring different types of loads within allowable stress 1- The concept of the load-bearing structure. range of the material with a factor of safety. 2- The determination of the input loads. 3- Implementation of different theories for the static loading of The idealized representative structural model of the the structure and the strength of the body and its joints. principal internal structural load carrying members is obtained so as to give a simple and yet accurate representative The first part of the structural stress analysis is the study of the idealization of a generic real sedan car body structure [2]. This load-bearing structure. The general description of the car body idealization is then applied on a real existing saloon car “Nasr structural components under consideration in this paper and its DOGAN 1.6 liter “ to obtain its structural model. The cross- three subassemblies are discussed followed by the descriptions of sectional properties and gravimetric analysis need to be the structural model idealization. specified in the model as a part of the idealization of vehicle body structural model and to be used in the stress analysis that Keywords — Monocoque, Car Body Structural Analysis, Finite depends mainly on these cross-sectional properties. Element Analysis, Thin-walled structure, Optimization Analysis. II. METHOD OF APPROACH I. INTRODUCTION The vehicle body structure is considered to consist of three The main objectives in car structural design are to obtain a subassemblies in series (Frontal part, Central (passenger minimum weight design which makes the best use of material compartment) part, and Rear part). Both the front-end and the by arranging for each member to support as near as possible its rear-end assemblies should have relative lower stiffness than maximum load potential, to make the structure direct and the central part to form the crumple zones in case of collision, continuous by providing an unbroken path from point of [1],[5],[6] application to point of reaction, to minimize weight; by Maintaining the Integrity of the Specifications spreading concentrated loads as much as possible; which are The template is used to format your paper and style the text. efficiently distributed to react applied load with the minimum All margins, column widths, line spaces, and text fonts are redundancy, to avoid buckling of the thin sheet materials in prescribed; please do not alter them. You may note monocoque structure type, and to provide passenger protection peculiarities. For example, the head margin in this template in accidents. [1] measures proportionately more than is customary. This Although the modern passenger car, due to aerodynamic measurement and others are deliberate, using specifications that and styling requirements has surfaces with high curvature, the anticipate your paper as one part of the entire proceedings, and structure behind these surfaces can be approximated to not as an independent document. Please do not revise any of components or subassemblies that can be represented as plane the current designations. surfaces. [3] IJERTV7IS090048 www.ijert.org 131 (This work is licensed under a Creative Commons Attribution 4.0 International License.) Published by : International Journal of Engineering Research & Technology (IJERT) http://www.ijert.org ISSN: 2278-0181 Vol. 7 Issue 09, September-2018 I. PREPARE YOUR PAPER BEFORE STYLING The central part (passenger compartment) comprises of the Before you begin to format your paper, first write and save main floor panel assembly, side frame, and roof panel. The the content as a separate text file. Keep your text and graphic bulkhead towards the front and rear complete the box-like files separate until after the text has been formatted and styled. form. The curved shape of the roof panel prevents to be in a Do not use hard tabs, and limit use of hard returns to only one lozenge (going out of alignment in a diamond shape). Side frame assemblies reinforce the floor pan along the sill sections which consist of the A-post, the BC-post, the D-post, and the- rear quarter section The rear-end assembly consists of the rear wheel arch integrated with quarter section, the rear seat heel board (rear bulkhead) forming a closed torsion box with boot floor and rear panel assembly. The following are the steps of the idealized representative structural model for the principal internal structural load carrying members, which give a simple yet accurate representative idealization of a generic real sedan passenger car body structure [7]. 1 - The idealized structure is a combination of Frameworks (such as the edges of larger openings as Doors, Windows) and Shell constructions (which are combinations of Beam sections and Skin panels, in which the skin plays a major part in carrying loads and the beams to take up the concentrated loads) that must be represented by Thin-Walled Shell Structures in the final design stage, and by a simplified one during the first stage as Structural Surfaces. 2 - The side frame is a flat stiff frame, then one shear panel is sufficient to take up the reaction at the upper front and rear bulkheads as shown in Fig.2 [8] Fig . 1. Body shell assembly for a saloon monocoque closed integral structure. 1 Underbody assembly. 2 Body side frame assembly. 3 Windscreen rail assembly. 4 Cowl and dash panel assembly. 5 Fr. wheel panel assembly. 6 Windscreen rail assembly. 7 Cowl side lower brace. 8 Lower A-pillar. 9 Roof panel assembly. 10 Roof bow assembly. 11 Rear bulkhead brace assembly 12 Rear quarter panel assembly. 13 Rear window UPR rail. 14 Rear cowl assembly. Fig .2. The front bulkhead stiffened with one auxiliary structural surface 15 Radiator panel assembly. 16 Central pillar (BC-post). 3 - The introductions of the forces from the front suspension 17 D-post. 18 Rear quarter assembly. into the front bulkhead are through the valance with built-up 19 Sill panel. 20 Front side member assembly. horizontal panels as shown in Fig.3. [3] 21 Rear wheel arch assembly. 22 Main floor assembly. 23 Valance complete assembly. 24 Front cross member. 25 Front bumper. 26 Upper A-pillar. 27 Rear seat panel. 28 Central (transmission) tunnel. 29 Rear seat cross-member. 30 Spare wheel well. 31 Rear suspension support. 32 Longitudinal rail. The front-end assemblies made up from: the two front side wheel panel assemblies which are connected to the front bulkhead and enclosed by the front cowl (or dash panel) at the rear and at the front by the radiator panel assembly, while the engine cross member assembly is a transverse beam that transfers the engine’s weight to the longitudinal members of the front-end panel assembly. It is attached to the main floor panel at the toe panel, and by two lower supporting forks. Fig.3. Introduction of forces into the front bulkhead by means of a built up wings; b- vertical load, c-longitudinal load, d-Side loads Showing the internal shear forces, and the corresponding reactions on the surrounding shear panels. IJERTV7IS090048 www.ijert.org 132 (This work is licensed under a Creative Commons Attribution 4.0 International License.) Published by : International Journal of Engineering Research & Technology (IJERT) http://www.ijert.org ISSN: 2278-0181 Vol. 7 Issue 09, September-2018 4 - The base element of a closed structure is the side-frame [A- 8-There are several areas that are ‘closed-boxlike’ structure that B-C-D-E-F] which transfers bending, have 6-times degree of will be connected to the side frame which will provide redundancies as shown in Fig.4. [3] additional torsional stiffness to the overall structure, namely: 5 - Side frame with load bearing panel (D-post) l-D-E-J to 1-the engine and luggage compartments, and 2-cowl and compensate the decreased bending stiffness of windscreen footwell assembly (the region enclosed by the front pillar and also through increasing the remaining sections of bulkhead, cowl, lower A- pillar, and floor) as shown in Fig.7.
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