International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

DESIGN AND ANALYSIS OF HEAVY VEHICLE CHASSIS

USING HONEY COMB STRUCTURE

K.Rajesh 1, K.Durga2,
1 Research Scholar, Department Of Mechanical Engineering, Vikas college of Engineering and Technology,Vijayawada rural,A.P,India
2 Assistant professor , Department Of Mechanical Engineering, Vikas college of Engineering and Technology,Vijayawada rural,A.PIndia

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.
This thesis deals with the design optimization and material suggestion for heavy vehicle chassis (container vehicle).
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:
K.Rajesh ,
Research Scholar, Department Of Mechanical Engineering,
Vikas college of Engineering and Technology,
Vijayawada rural,A.P,India.
Published: December 22, 2014
Review Type: peer reviewed
Volume: I, Issue : IV

Citation: kaile.rajesh, Research Scholar (2014),Design

And Analysis Of Heavy Vehicle Chassis Using Honey
Comb Structure

Problem discripition
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
As 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
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:
Chassis 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
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International Journal of Research and Innovation (IJRI)

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:

Computer-aided design (CAD) is defined as the application of computers and graphicsSoftware to aid
or enhance the product design from conceptualization to documentation.CADis most commonly associated with the use of an interactive computer
graphics system, referred toas a CAD system. Computer-aided design systems are powerful tools and
in the mechanicaldesign and geometric modeling of
products and components.
There are several good reasons for using a CAD system to support the engineering design function:
To increase the productivity
To improve the quality of the design
To uniform design standards
To create a manufacturing data base
To eliminate inaccuracies caused by hand-copying
of drawings and inconsistency between
Drawings
MODEL OF EXISTING CHASSIS

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
WELDING IMPROVEMENTS
As most body shells are manufactured by spot welding the panels together, a simple way to stiffen them
up is to either stitch or seam weld them instead. As
with welding during construction of a chassis, care
must be taken to avoid problems due to excessive
heat. Normally, additional welding is concentrated
on specific areas, such as suspension mounting
points or the engine bay, as it is quite a labor intensive technique. Most of the time, a full rollcage
would be fitted instead of additional welding, but
in some instances where a cage is not going to be
used, full welding of the entire shell can take place.

The above image shows final model of existing chassis

MODEL OF MODIFIED CHASSIS

INTRODUCTION TO CAD
Throughout the history of our industrial society,
many inventions have been patented andWhole new
technologies have evolved. Perhaps the single development that has impactedManufacturing more
quickly and significantly than any previous technology is the digital computer.
Computers are being used increasingly for both design and detailing of engineering components
in the drawing office.

The above image shows final model of modified

chassis

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International Journal of Research and Innovation (IJRI)

The above image shows detail of modified chassis

MODEL OF HONEY COMB CHASSIS

The above image shows 2d drafting of modified

chassis

The above image shows 2d drafting of honeycomb

chassis
The above image shows final model of honeycomb chassis

The above image shows detail of honeycomb chassis

2D DRAWINGS OF MODELS

INTRODUCTION TO FEA
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. 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.
STRUCTURAL ANALYSIS ON EXISTING DESIGN
OF CHASSIS
MILD STEEL

The above image shows 2d drafting of existing chassis

The above image is the imported model of chassis.

Modeling was done in Pro-E and imported with the
help of IGES (Initial Graphical Exchanging Specification).
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International Journal of Research and Innovation (IJRI)

The above image showing the meshed modal. Default solid Brick element was used to mesh the components. The shown mesh method was called Tetra
Hydra Mesh.
Meshing is used to deconstruct complex problem
into number of small problems based on finite element method

The above image shows von-misses stress value

12.426 N/mm2

LOAD: 20 TONS

The above image shows strain value 0.0000592

FATIGUE ANALYSIS ON EXISTING DESIGN OF
CHASSIS

The above image shows the loads applied

RESULTS
Displacement

The above image shows safety factor value 15

The above image shows displacement value 1.4895

mm
The above image shows Biaxiality indication value
0.91413
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International Journal of Research and Innovation (IJRI)

The above image shows alternating stress value

24.853

The above image shows strain value 0.00014155

STRUCTURAL ANALYSIS ON EXISTING DESIGN

OF CHASSIS

FATIGUE ANALYSIS ON EXISTING DESIGN OF

CHASSIS

E glass epoxy

The above image shows displacement value 4.3332

mm

The above image shows safety factor value 15

The above image shows von-misses stress value

12.398 N/mm2

The above image shows Biaxiality indication value

0.91305

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International Journal of Research and Innovation (IJRI)

The above image shows alternating stress value

24.795

The above image shows strain value 0.0000143

STRUCTURAL ANALYSIS ON EXISTING DESIGN

OF CHASSIS

FATIGUE ANALYSIS ON EXISTING DESIGN OF

CHASSIS

S glass epoxy

The above image shows displacement value 0.36075

mm

The above image shows safety factor value 15

The above image shows von-misses stress value

12.406 N/mm2

The above image shows Biaxiality indication value

0.9424

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International Journal of Research and Innovation (IJRI)

MODIFIED
Mild Steel

E-Glass

S-Glass

Displacement

1.640

4.7729

0.39734

Stress

12.509

12.644

12.531

Strain

6.377 e-

0.000190

1.5744 e-5

SafetyFactor
= yelidstrenght/stress

43.968

39.544

365.89

Biaxiality
indication

0.99532

0.992

0.9961

Alternative
Stress

25.017

25.289

25.2062

HONEY COMB

The above image shows alternating stress value

24.812
STRUCTURAL ANALYSIS ON HONEY COMB DESIGN OF CHASSIS
MILD STEEL

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

SafetyFactor
= yelidstrenght/stress

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: S-GLASS EPOXY

The above image is the imported model of chassis.

Modeling was done in Pro-E and imported with the
help of IGES (Initial Graphical Exchanging Specification).
RESULTS TABLES
EXISTING
Mild Steel

E-Glass

S-Glass

Displacement

1.489

4.333

0.360

Stress

12.426

12.398

12.406

Strain

5.928e-5

0.0001715

1.4305 e-5

SafetyFactor
= yelidstrenght/stress

44.262

40.329

369.57

Biaxiality
indication

0.914

0.913

0.9242

Alternative
Stress

24.853

24.795

24.812

material

existing

modified

Honey comb

displacement

83905

1.3107e

4.8526e5

stress

16.869

16.917

47.382

strain

0.000021605

0.000021617

0.000054645

CONCLUSION
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.
Firstliteraturesurvey 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 struc74

International Journal of Research and Innovation (IJRI)

ture 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.
BIBLIOGRAPHY
1.1Manpreet singh bajwa, 2yatin raturi, 3amit
joshi(1)
2.1Hemant kumar nayak, 2nagendra prasad, 3
deepty verma,4tulsi bisht
3.Thanneru raghu krishna prasad, gouthamsolasa,
nariganani sd satyadeep, g.Sureshbabu
4.Hirak patel, khushbu c. Panchal, chetan s. Jadav
5.Hemant
b.Patil1,
sharad
d.Kachave2,
eknath
r.Deore3
1(p.G.Student
mechanical, s.Sv.P.S.B.S.D.C.O.Engg, dhule north maharashtra
university,
india)
2(mechanical,
s.Sv.P.S.B.S.D.C.O.Engg, dhule north maharashtra university, india) 3(head of mechanical,
s.Sv.P.S.B.S.D.C.O.Engg, dhule north maharashtra
university, india)

Authour

K.Rajesh
Research Scholar,
Department Of Mechanical Engineering,
Vikas college of Engineering and Technology,
Vijayawada rural,A.P,India

6.Prajwal kumar m. P1, vivek muralidharan2, g.

Madhusudhana3
7.
Haval kamal asker1, thakersalih dawood1
and arkanfawzi said2
8.Mukeshkumar r. Galolia, 2 prof. J. M. Patel
9.Sairamkotari 1, v.Gopinath2
10.Mohdazizi muhammad nora,b*, helmirashida,
wan mohdfaizul wan mahyuddinb,
Mohdazuanmohdazlanc, jamaluddinmahmuda
11.Alireza arab solghar*, zeinabarsalanloo
12E.Bhaskar 1, t.Muneiah 2, ch.Venkata rajesh3
13. Haiping du, weihua li, nong zhang, du, h., Li,
w. & Zhang,

K.Durga
Assistant Professor,
Department Of Mechanical Engineering,
Vikas college of Engineering and Technology,
Vijayawada rural,A.P,India

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