Design and Analysis of Heavy Vehicle Chassis by Using Materials Steel & S-Glass M.Nagaraju Ch.Ashok K.Veeranjaneyulu M.Tech (Machine Design), Assistant Professor, Associate Professor & HOD, Anurag Engineering College, Dept of Mechanical Engineering Dept of Mechanical Engineering, Kodad, T.S, India. Anurag Engineering College, Anurag Engineering College, Kodad, T.S, India. Kodad, T.S, India. ABSTRACT: The automobile is divided into two parts body and It gives strength and stability to the vehicle under chassis. The chassis is basic structure of a vehicle. It different conditions. Automobile chassis is usually contains all the engine parts and power systems but the made of light sheet metal or composite plastics. It frame is the main portion of chassis which do not provides strength needed for supporting vehicular contain any other assemblies like engine parts. Its components and payload placed upon it. Automotive principle function is to safely carry the maximum load chassis or automobile chassis helps keep an for all designed operating conditions. Composite automobile rigid, stiff and unbending. It ensures low material is a material composed of two or more distinct levels of noise, vibrations and harshness throughout phases and having bulk properties significantly the automobile. Automobile chassis without the wheels different from those of any of the constituents. and other engine parts is called frame. Automobile Different types of composite material are available and frames provide strength and flexibility to the one of it is Polymer matrix composite. It has the automobile. The backbone of any automobile, it is the benefits of high tensile strength, high stiffness and supporting frame to which the body of an engine, axle good corrosion resistance etc. At present this polymer assemblies are affixed. Tie bars that are essential parts matrix composite materials are used in aerospace, of automotive frames are fasteners that bind different automobile industries due to it high strength to low auto parts together. Automotive frames are basically weight ratio. In the present work, the dimensions of an manufactured from steel. Aluminum is another raw existing heavy vehicle chassis of a TATA 1109 EX2 material that has increasingly become popular for vehicle is taken for modeling and analysis. The vehicle manufacturing these auto frames. In an automobile, frame is initially modeled by considering „C‟ cross front frame is a set of metal parts that forms the section in SOLID WORKS 2014 then it is imported to framework which also supports the front wheels. ANSYS 13.0. The analysis is done with two different composite materials namely Steel and S-glass/Epoxy Automotive chassis is a skeletal frame on which subjected to the same pressure as that of a steel frame. various mechanical parts like engine, tires, axle The design constraints are stresses and deformations. assemblies, brakes, steering etc. are bolted. The chassis The results are then compared to finalize the best is considered to be the most significant component of among all the four frames. an automobile. It is the most crucial element that gives strength and stability to the vehicle under different I. INTRODUCTION: conditions. Automobile chassis provide strength and Automotive chassis is a French word that was initially flexibility to the automobile. The backbone of any used to represent the basic structure. It is a skeletal automobile, it is the supporting frame to which the frame on which various mechanical parts like engine, body of an engine, axle assemblies are affixed. Tie tires, axle assemblies, brakes, steering etc. are bolted. bars, that are essential parts of automotive frames, are fasteners that bind different auto parts together. Page 736 Problem Identification The C‐glass is for high corrosion resistance, and it is Weight reduction is now the main issue in automobile uncommon for civil engineering application of the industries. At the same time as the weight of the three fibers, the E‐glass is the most common vehicle increases the cost also increases which reinforcement material used in civil structures. It is becomes a major issue while purchasing an produced from lime‐alumina borosilicate which can be automobile. For example if we take frame of TATA easily obtained from abundance of raw materials like 1109 EX 2 heavy vehicle frame. It is manufactured sand. The glass fiber strength and modulus can with Structural Steel. Steel structures exposed to air degrade with increasing temperature. Although the and water, such as bridges are susceptible to corrosion. glass material creeps under a sustained load, it can be In conditions of repeated stress and more temperatures designed to perform satisfactorily. The fiber itself is it can suffer fatigue and cracks. These are the main regarded as an isotropic material and has a lower problems of steel and these are compensated by thermal expansion coefficient than that of steel. inducing composite materials. Steel FRP Composites FRP composites are defined as the materials that Stainless steels contain a minimum of 11% chromium, consist of fibers embedded in a resin matrix. The aim often combined with nickel, to resist corrosion. Some of combining fibers and resins that are different in stainless steels, such as the ferrite stainless steels are nature is to take advantage of the distinctive material magnetic, while others, such as the austenitic, are features of either component to result in an engineered nonmagnetic. material with desired overall composite action for Composition of steel specific applications. Such a composite is considered to be a discontinuous fiber or short fiber composite if Table – I its properties vary with fiber length. Constituent Weight Particular types of fibers applications: Percentage Load‐bearing capacity, level of exposure, wear Si 1.8 resistance, temperature and frequency ranges, fire and water resistance and costs are some of the important C 0.565 issues that need to be thoroughly considered. Various advantages of composite materials are its high specific Mn 0.7 stiffness and high specific strength. These properties are generally used in structural application such as P 0.045 aerospace and sporting goods. S 0.045 Glass Fibers: Impurities Traces The most common reinforcement for the polymer matrix composites is a glass fiber. Most of the fibers are based on silica (SiO2), with addition of oxides of Mechanical Properties of Steel Ca, B, Na, Fe, and Al. The E‐glass is designated for Table – II electrical use and the S‐glass for high strength. Page 737 Properties STEEL In an automobile, front frame is a set of metal parts Young‟s modulus (GPa) 190-210 that forms the framework which also supports the front Shear modulus, G12 (GPa) 75-80 wheels. It provides strength needed for supporting Major Poisson‟s ratio, υ12 0.30 vehicular components and payload placed upon it. Minor Poisson‟s ration, υ21 0.27 Shear moulus, S (GPa) 80 Different types of automobile chassis: Ladder Chassis: S-glass: Ladder chassis is considered to be one of the oldest forms of automotive chassis that is still used by most Fibers have a magnesium alumino‐silicate of the SUVs till today. As its name connotes, ladder composition, which demonstrates high strength and chassis resembles a shape of a ladder having two used in application where very high tensile strength longitudinal rails inter linked by several lateral and required. cross braces.The truck frame allows different types of truck beds or enclosures to be attached to the frame. Typical Properties of E-Glass and S-Glass For larger trucks, the frames are simple, rugged, and of channel iron construction. The side rails are parallel to Table – III each other at standardized widths to permit the mounting of stock transmissions, transfer cases, rear Typical Properties S-Glass axles, and other similar components. Trucks that are to be used as prime movers have an additional 3 Density (g/cm ) 1.6 reinforcement of the side rails and rear cross members to compensate for the added towing stresses. Young‟s Modulus (GPa) 87 Backbone Chassis: Tensile Strength (GPa) 2.53 Backbone chassis has a rectangular tube like backbone, usually made up of glass fibre that is used Tensile Elongation (%) 2.9 for joining front and rear axle together. This type of automotive chassis or automobile chassis is strong and powerful enough to provide support smaller sports car. II. INTRODUCTION TO CHASSIS Backbone chassis is easy to make and cost effective. Automotive chassis is a skeletal frame on which A backbone chassis like this can actually be slightly various mechanical parts like engine, tires, axle stiffer than a space frame of the same weight. assemblies, brakes, steering etc. are bolted. The chassis However, because the chassis has to fit within the is considered to be the most significant component of confines of the centre of the body, it can only be made an automobile. Automobile frames provide strength so stiff. As such, it tends to lend itself better to small and flexibility to the automobile. The backbone of any or medium sized vehicles, as large, powerful cars do automobile, it is the supporting frame to which the not necessarily have enough of a proportional increase body of an engine, axle assemblies are affixed. Tie in the room available for the central backbone to allow bars, that are essential parts of automotive frames, are it to be scaled up to cope with the increased loads. fasteners that bind different auto parts together. Automotive frames are basically manufactured from Monocoque Chassis: steel. Aluminum is another raw material that has Monocoque Chassis is a one-piece structure that increasingly become popular for manufacturing these prescribes the overall shape of a vehicle. This type auto frames. Page 738 of automotive chassis is manufactured by welding SPACE-FRAME CHASSIS floor pan and other pieces together. Since As we mentioned, the problem with a ladder-frame monocoque chassis is cost effective and suitable for chassis is that, although strong, it isn't very stiff.