A Methodological Study to Analyze and Design the Car Chassis

The car's chassis is also called a structure that locates and mounts all the vehicle's components. It also creates a secure environment for the occupants. The chassis will provide torsional and flexural rigidity to the vehicle that makes the chassis one of the most crucial elements of the vehicle. Therefore, the front impact, rear impact, side impact, front torsional, rear torsional, vertical bending, lateral bending analyses were performed. The contribution of chassis is not limited to supporting the vehicle’s component, but it extends to providing better performance and aesthetics. Therefore, the design of the car chassis must be done accordingly. The current paper deals with the study of the design and analysis of the race car. The deformation, stress, and Factor of safety were considered as the evaluation parameters which were obtained by Finite Element Analysis (FEA) in Ansys software. To design the chassis, the SolidWorks software was utilized. Keywords: Car Chassis, Design, FEA, Material Comparison.

Ballistic characterization of fiber elastomer metal laminate composites and effect of positioning of fiber reinforced elastomer

The present study aims at investigating the ballistic impact response of jute, natural rubber and aluminium based tri-layer composites with two different configurations, namely Aluminium-Jute-Rubber-Jute and Jute-Rubber-Jute-Aluminium. The proposed composites were fabricated using the compression moulding technique and subjected to ballistic impact testing at impact velocities of 75 m/s, 105 m/s, 154 m/s and 183 m/s. The energy absorption and damage mitigation characteristics of the proposed fibre metal elastomer tri-layer composites were assessed. Results showed that among the two proposed composites, the composite with rubber facing the impact side exhibits better energy absorption and also helps in damage mitigation compared to the composite having aluminium on the impact side. In addition, a parametric study was carried out by varying the thickness of the rubber layer. It was observed that the impact response of the proposed tri-layer composites improved with increasing thickness of the rubber layer, especially in the case of the Jute-Rubber-Jute-Aluminium configuration.

Failure mechanism of Ω-shape 3D orthogonal woven composite component under transverse low-velocity impact and subsequent axial compression load

Failure mechanism of complex profile component is always different from that of conventional plate counterpart due to the coupling effect of material and structure. In this work, the low-velocity impact (LVI) and compression after impact (CAI) behaviors of Ω-shape hybrid carbon/Kevlar 3 D orthogonal woven (3DOW) composite made for vehicle B-pillar were comprehensively studied by mechanical tests and mesoscale finite element (FE) analysis at component level, high-speed infrared (IR) thermal imaging, acoustic emission (AE) detection, and microscopic damage morphology characterization. It is found that a through-thickness stress concentration ring leads to high stress state and damage zone penetrating from the impact side to non-impact side along the ring path instead of at the lowest impactor position. The slope effect can not only help the stress conduction downward, but also inhibit the damage propagation from the impact side to the slope. Impact-induced cracks are concentrated around the R corners and extended along the axial direction of the specimen, forming the strip-shaped damage concentration zone along the upper eave of the slope. The Progressive Top-Down Crushing (PTDC) mode of compression after impact is due to the complex deformation process of each yarn such as squeezing, folding and eversion in the crushing process from the top of specimen. And the Middle Indentation Fracture (MIF) mode is the result of bending instability and abrupt fracture. This work presents a reference significance for the further development of composite strengthening components in vehicle bodywork.

Design and Analysis of Eco Car Chassis with Different Profiles

Formula Student Racing competitions are held at various Formula SAE circuits globally. Chassis serves as an important component in the race car design. Thus a solicitous analysis is expected out of the formula car. It is also noted that the weight of the car is inversely proportional to the performance of the car hence need for optimization. A high speed protection system plays a major role in the race car design such as front impact, rear impact, side impact and roll over analysis. Also, there exists a problem of the torsional rigidity as far the dynamics is considered. This paper aims at the design aspects and the analysis insights of the race car. The car is modelled according to the 95th percentile male that can fit inside the cockpit of the chassis. As the car travel at the high speed, the protection has been designed to the car in such a way that stresses are minimum and the performance is maximum. Finite element methods are used for the analysis and the design of experiments is created for the optimization of the chassis. To avoid any possibilities of failure of the structure and thus to provide enough supporting member to make the region stronger in term of deformation . Finite element analysis enables to predict the region that tends to fail due to loading, the distribution of stress and strain on the chassis, both component as well as the material costing. The main objective is to study the effect of the validations of the FEM result are given using the different profiles like RECTANGLE, CIRCULAR, AND I SHAPE convergence methods for car body and the equipment. Keywords:-Chassis design; cross sections; Static analysis; Model analysis

Crashworthiness of Traffic Light Steel Poles in Vehicle Collisions

Vehicle crashworthiness focuses on the capability of a vehicle to protect its occupants in a collision. The Canadian Highway Bridge Design Code [2] does not provide design criteria for vehicle occupant safety except by field testing. The test-guided product development process is very costly and time-consuming. As an alternative, computer simulation tools are increasingly being used. The aim of this research is to contribute to the efficient design of traffic light poles by developing an experimentally calibrated, computer-based, finite-element model using LSDYNA [54], capable of predicting accurately their response when subjected to vehicle impact. The case of steel pole embedded directly in soil was proved to be strong enough to offer protection under service loading and vehicle impact. Side impact crashed proved to be more severe for the vehicle occupant as a result of the weak structural performance of the side doors of the vehicle. Based on this an innovative pole supported on a hard rubber base is introduced to improve crashworthiness.

Crashworthiness of Traffic Light Steel Poles in Vehicle Collisions

Vehicle crashworthiness focuses on the capability of a vehicle to protect its occupants in a collision. The Canadian Highway Bridge Design Code [2] does not provide design criteria for vehicle occupant safety except by field testing. The test-guided product development process is very costly and time-consuming. As an alternative, computer simulation tools are increasingly being used. The aim of this research is to contribute to the efficient design of traffic light poles by developing an experimentally calibrated, computer-based, finite-element model using LSDYNA [54], capable of predicting accurately their response when subjected to vehicle impact. The case of steel pole embedded directly in soil was proved to be strong enough to offer protection under service loading and vehicle impact. Side impact crashed proved to be more severe for the vehicle occupant as a result of the weak structural performance of the side doors of the vehicle. Based on this an innovative pole supported on a hard rubber base is introduced to improve crashworthiness.

Buggy Role Cage – Analysis and Design

Design and analysis of Buggy roll cage commonly used as a recreational vehicle on off road terrains have been studied. These vehicles are usually modified from their existing design to provide performance and safety. In this research paper, an attempt has been made to design a roll cage for a buggy considering different members of the roll cage. In this context roll cage has been drawn on solid works CAD software and has been analyzed using finite analysis by applying the different boundary conditions. The roll cage has been designed considering the AISI 4130 steel and carbon fiber considering five cases such as front impact, side impact, rear impact, drop test and roll over test to ensure safety of the operator to survive the impact scenario. The main significance of this study is to analyze buggy role cage from safety point of view of operator. From these results it can be concluded that carbon fiber roll cage is also one of the promising alternatives for roll cage design and can be recommended from safety point of view.

Crash Analysis of Bus Body Structure using Finite Element Analysis

Crash analysis of non-air-conditioned sleeper bus has been carried in present work. Using relevant automotive industry standards (052 and 119) bus dimensions are considered for design. Surface modeling technique is used to prepare computer aided model. Further the bus design is freeze using finite element analysis for different crash conditions as front impact, side impact and rear impact. Crash analysis of the proposed bus design is carried using Ansys Workbench. Using the outcomes from finite element analysis as stresses, deflections, internal and kinetic energies during various crash conditions are estimated. Mesh generator is used to mesh the complex bus model. The stress and deflection magnitudes of proposed bus model are in good agreement with the experimental results available in literature. Design improvements are made using the finite element analysis outcomes, observing the deformation patterns additional pillar members of suitable length are added to increase the dynamic crush and further enhance occupant safety during collisions.

Análisis estructural de chasis prototipo para automóvil tipo SAE BAJA

In the present work, the numerical analysis of the structure of a prototype of a SAE BAJA type automobile chassis is developed. Within the proposal of the model, factors that become important when implementing it are considered, these factors are: driver safety, sufficient spaces for vehicle components, among other basic points. Likewise, the model is subjected to different tests established by the Society of Automotive Engineers (SAE), tests such as: Front impact, rear impact, side impact, overturn, landing tests for front jump and rear jump; the conditions to which these tests are subjected are extracted from articles (tests) and applied in the appropriate areas to have the most accurate and close to reality results. The analysis is carried out with different materials and profiles used for structural members, in this way the appropriate configuration of the profiles and materials is also obtained. Due to the satisfactory parameters obtained, a fairly efficient model is obtained, this has an impact on the necessary safety for the driver, basically, because the system has low deformations in the materials and withstands relatively high stresses.

Parameters of Side Intrusion Beam Affecting on Crash Force Efficiency During Impact

Occupants safety is one of the most important criteria in car design. Due to the less space between occupant and side door, the scope of energy absorption is less. Hence in a case of side impact, the strength of side door is plays crucial role. A side intrusion beam is mount inside the side door and is also called side impact beam. During side impact, side intrusion beam gets deformed and it absorb the highest amount of energy compare to others parts of side door. And also for smooth bending during the impact, nearly equal amount of force should absorb during the whole bending process. So design of side intrusion beam is important part of vehicle door design. The various parameters of intrusion beam like, material of intrusion beam, shape of intrusion beam, dimensions, mounting of beam inside the door etc. are affected on the strength of side door. In present work using finite elements analysis the effect of important parameters of hollow circular cross section side intrusion beam on Crash Force Efficiency (CFE) is studied. The ABAQUS software is used to perform various finite element simulation. In the first part of this work most influential parameter is determine by Design of Experiments and ANOVA analysis, in a second part of this work relative effect of this influential parameter on crashworthiness of side intrusion beam is studied.