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International Journal of Science and Engineering Research (IJ0SER),

Vol 4 Issue 4 April-2016 3221 5687, (P) 3221 568X

Eswaran,Dinakaran,Jeevankumar,Karthick, (IJ0SER) April – 2016

Design And Structural Analysis Of Heavy Duty Vehicle

Fornt Axle 1 S. Eswaran ,

2 B.Dinakaran ,

2 L.Jeevankumar ,

2 K.P.Karthick ,

2 S.Karthick

1 Assistant professor,

2 UG Scholars,

Department of Mechanical Engineering,

Nandha Engineering College, Erode,

India

Abstract- Weight reduction plays an important role in automobile components. When the weight of the vehicle is

reduced then the fuel consumption of the particular vehicle will be decreased. If the fuel consumption rate is

increased then the emission rate also increases. The following factors that mostly affects the emission from the

engine includes vehicle class, weight, driving cycle, vehicle vocation, fuel type and vehicle age. Due to this the

researchers have given more importance for produce light weight components. This research attempts to reduce

the weight of the front axle of a heavy duty vehicle. The weight is reduced by changing the front axle design

slightly without sacrificing its strength. By minimizing the weight of the component the fuel consumption rate is

reduced by 5-10%.the design was done using CATIA and meshed in HYPERMESH software module. The

meshed model was solved in ANSYS software.

Keywords: modeling, analysis, comparison of results.

A. INTRODUCTION:

The automobile industry is the most important

field of Indian economy. The automobile components are

used in commercial vehicles, multi-utility vehicles, passenger cars, two wheelers, three wheeler Due to the

economical reason it is necessary to optimize the vehicle

design. The design engineer initially need to meet safety

requirements and later to reduce the weight of the automobile component for improving the fuel economy.

It is necessary that the axles should resist against the

fatigue failure for a predicted service life. Axle experiences various loads like bending load, payload and

torsion. These loads are varying with respect to time.

Usually the normal load about 35-40% of the weight of the vehicle is acting on the front axle.

While applying the break about 60% of the

vehicle weight is acted on the front axle. Due to this higher loading capacity Solid axles are most commonly

used in heavy duty commercial vehicles. Performing the

physical test for bending load is costly and time consuming. So there is a need to build Finite element

models which can virtually simulate these loads and

predict the behavior. The finite element analysis produce

accurate results, this accurate result purely depends upon the accuracy of input conditions.

Front axle is one of the important parts of vehicle

suspension system. In this research work design of the

front axle for Tata LPT2518 6X4 heavy commercial vehicle were done. The approach in this project has been

divided into two types.

In the first step front axle was design by analytical method. For this, the vehicle specifications, its

gross weight and payload capacity in order to find the

stresses and deflection in the beam has been used. In the second step front axle were modeled in CATIA and

meshed in HYPERMESH software module. The meshed

model was solved in ANSYS software. The FE results were compared with analytical design.

B.COMPONENTS:

For design purpose the front axle beam of the tata

truck was selected. All types of standard front axle have an I cross section in the middle and circular or elliptical

cross section at the ends. The I section will gives high

strength with lower weight. This type of construction used in front axle that is light weight and yet has great

strength. On the top of the front axle two leaf springs are

mounted on a flat, smooth surfaces or pads. The mounting

place of the spring is called spring seat and it is usually consist of five holes. The four holes on the outer edge of




the mounting surface are for the U bolts which hold the

spring and axle together.

Top view of fornt axle

Side view of front axle

C.MATERIAL SPECIFICATION:

Now a days the front axle is usually made of steel. The

properties of steel is given below

Density 7.85e-006kg mm^-3

Co efficient of thermal

expansion

1.2e-005c^-1

Specific heat 4.34e+005 mJ kg^-1 C^-1

Thermal Conductivity 6.05e-002 W mm^-1 C^-1

Resistivity 1.7e-004 ohm mm

Compressive Ultimate Strength MPa

0

Compressive Yield

Strength MPa

250

Tensile Yield Strength MPa

250

Tensile Ultimate

Strength MPa

460

Strength Coefficient

MPa

920

Strength Exponent -0.106

Ductility Coefficient 0.213

Ductility Exponent -0.47

Cyclic Strength Coefficient MPa

1000

Cyclic Strain Hardening

Exponent

0.2

Relative Permeability 1000

Young's Modulus MPa 2.1e005

Poisson's Ratio 0.3

D.DESIGN OF FRONT AXLE:

1.Existing model:

2.Optimized model:

E.FINITE ELEMENT ANALYSIS:




After finishing the optimized design using CATIA the

model was solved in ANSYS14.5 software. The displacement and stress has been plot in ANSYS14.5

software module.

1.Deflection in existing model:

2..Deflection in optimized model:

3.Von-mises stress for existing model:

4.Von-mises stress for optimized model:

F.CONCLUSIONS:

Existing

model

Optimized

model

Mass 104.72kg 95.868kg

Deflection 1.1823mm 0.019637mm

Von-mises stress 136.58Mpa 161.07Mpa




From the above table shows that the deflection and stress

distribution in optimized model is greater than the existing model hence the weight of the axle has been

reduced. Finally we were able to deliver a safe and

validate design to suit the requirements of the project.

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