Report on

Static Structural Analysis Chassis

(Suzuki Samurai SJ)

Submitted
In partial fulfillment of

The requirements for the CBE course in B.E

(Automobile Engineering)

By
Hitesh Watkare 780
Shubhank Patil 774
Akshay Patil 773
Bilal Khan 767

Under the Guidance of

Prof. Amey Marathe
Department of Automobile Engineering
PCE, New Panvel
 Static Structural Analysis of Suzuki Samurai Chassis
Hitesh Watkare, Shubhank Patil, Akshay Patil, Bilal Khan
Automobile Engineering Department, Pillai College of Engineering
Dr. K. M. Vasudevan Pillai Campus, Plot No. 10, Sector 16, New Panvel, Navi Mumbai, Maharashtra-410206
hwatkare@student.mes.ac.in
spatil49@student.mes.ac.in
aptil26@student.mes.ac.in
bkhan@student.mes.ac.in

Abstract--- This document gives information about the static and The design should also ensure the following:
dynamic analysis of Suzuki Samurai chassis. The base frame of a Ergonomically designed
car, carriage, or other wheeled vehicle is known as Chassis. A
Provision to manufacture with existing tooling, easy
chassis consists of an internal vehicle frame that supports an
manufacturability.
artificial object in its construction and use, can also provide
protection for some internal parts. Life of the vehicle, lesser maintenance.
Cost consideration, and weight consideration.
1. INTRODUCTION Using rationalized aggregates.
Adherence to CMVR rule for dimensions and locations.
Chassis is a major component of a vehicle system. It
consists of internal framework that supports man-made object. 2. CALCULATIONS
It is the underpart of the vehicle which consists of frame and
running gear like engine, transmission system, suspension Available data:
system etc. The automotive chassis is tasked with keeping all 1. Overall length: 3440 mm
components together while driving and transferring vertical and 2. Overall width: 1530 mm
lateral loads, caused by acceleration, on the chassis through 3. Wheelbase: 2030 mm
4. Track width: 1300 mm
suspension and the wheels. The key to good chassis design is
5. Kerb weight: 950 kg
that further the mass is away from the neutral axis the more 6. Gross weight: 1100 kg
rigid it is. For vehicles, chassis consists of an assembly of all
the essential parts of a vehicle (without the body) to be ready Sr no. Vehicle component Load (N)
for operation on the road. 1 Engine 716
Various types of chassis are present as follows: 2 Transmission 245
Ladder frame. 3 Passenger 1850
Unibody 4 Exhaust 200
Backbone tube. 5 Fuel tank 390
X-frame. 6 Luggage 7720
Platform frame.
Table 1: load distribution of Suzuki Samurai
Space frame.
Subframe.
Front impact load calculations:
Functions of Frame:
Packaging interface/platform for power package and Body To find front impact force (F) = (m x V0)/t
package. Provisions for mounting all the aggregates (support,
attachment, location, and alignment). Where,
Load bearing to carry the payload (principal function), Static m = mass of vehicle = 1100 kg
an Dynamic loads (braking, cornering, tipping and articulation) V0 = initial velocity of vehicle = 18.05 m/s
of the Mountings (aggregates, Load bodies etc.). The structure t = impulse time = 0.2 sec
should withstand all the loads with minimum structural material. F = (mxV0)/t
(more strength to weight ratio structures/sections) F = (1100 * 18.05)/ 0.2
The Loads are: F = 99275 N
Vertical Bending
Lateral Bending
Torsion
Horizontal Lozenging
 3. CAD DESIGNS MATERIAL PROPERTIES
SolidWorks modeling software is used around the world to
design products, develop machinery, and create production Aluminium Alloy
systems. The success of the software s application in industry
has led to its growing presence in education. Mechanical
engineering, industrial design, and transport technologies are
just a few of the functions in which SolidWorks software is Properties Value Unit
successfully used as an advanced tool by designers and
Density 2.7 g/cc
engineers. Building a model in SolidWorks usually starts with a
2D sketch (although 3D sketches are available for power users). Youngs Modulus 68.9 GPa
The sketch consists of geometry such as points, lines, arcs,
conics (except the hyperbola), and splines. Dimensions are Poissons Ratio 0.33
added to the sketch to define the size and location of the
geometry. Relations are used to define attributes such as Tensile Yield Strength 276 MPa
tangency, parallelism, perpendicularity, and concentricity. The
parametric nature of SolidWorks means that the dimensions and Tensile Ultimate Strength 310 MPa
relations drive the geometry, not the other way around. The
dimensions in the sketch can be controlled independently, or by Factor of Safety 2.5
relationships to other parameters inside or outside of the sketch.
Allowable Stress 124 MPa
Finally, drawings can be created either from parts or assemblies.
Views are automatically generated from the solid model, and
notes, dimensions and tolerances can then be easily added to the
drawing as needed.
4. FEA ANALYSIS
Finite element analysis (FEA) is one of the efficient and
well-known numerical methods for various engineering
problems. FEA was first developed in 1943 by R. Courant.
For the last 30 years it has been used for the solution of many
types of problems. FEA has become an integral part of
design process in automotive, aviation, civil construction
and various consumer and industrial goods industries, cut
throat competition in the market puts tremendous pressure
on the corporations to launch reasonably priced products in
short time, making them to rely more on virtual tools
(CAD/CAE) accelerate the design and development of
products.
The commercial software package ANSYS used as a FEA
tool in the stress analysis. The ANSYS program is a
powerful, multi-purpose analysis tool that can be used in a
wide variety of engineering disciplines. Using ANSYS
software can avoid expensive and time-consuming
development loops, so the design period is shortened.
We are here performing static structural solution on front
cross member and side members for calculating total
deformation and equivalent stress.
 STATIC DEFORMATON
Deformation refers to any changes in the shape or size of an
object due to-

an applied force (the deformation energy in this case is

transferred through work) or
a change in temperature (the deformation energy in this
case is transferred through heat)

Von Mises stress or equivalent tensile stress: Von Mises

stress is widely used by designers to check whether their design
will withstand a given load condition. Von Mises stress is
considered to be a safe haven for design engineers. Using this
information an engineer can say his design will fail, if the STATIC STRESS
maximum value of Von Mises stress induced in the material is
more than strength of the material.

DETAILS OF MESH

Relevance 40
Initial Size Seed Active Assembly
Smoothing Medium
Span Angle Center Fine
Transition Fast
Minimum Edge Length 1.28550mm
Nodes 33477
Elements 15686 DEFORMATION UNDER IMPACT TEST
 STRESS UNDER IMPACT TEST STRESS UNDER ENGINE AND PASSENGER

5. RESULT AND CONCLUSION

The analysis was carried out to study the structural integrity of

the Suzuki Samurai SJ Chassis to identify the maximum
stressed locations under loading conditions. Chassis was also
tested for frontal impact at 65 kmph and following results are
obtained.

Sr Test Total Stress in

no. deformation in MPa
mm
1 Static analysis 0.1403 1.3585
2 Impact test 55.935 188.37
Table 2: RESULT
CENTER OF GRAVITY
Since the resultant stress is greater than the allowable
stress, it can be concluded that the Chassis is not safe under
frontal impact at 65 kmph.

6. REFERENCES

http://www.4x4brasil.com.br/forum/attachments/suzuki/26
0625d1293748287-dados-suzuki-samurai-
samurai_1994.pdf
https://www.auto-data.net/en/?f=showCar&car_id=16423
http://asm.matweb.com/search/SpecificMaterial.asp?bassn
um=ma6061t6
http://www.pirate4x4.com/forum/suzuki/762420-samurai-
frame-body-weight.html

DEFORMATION UNDER ENGINE AND PASSENGER