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Kiran Maddewad1, Trupti Jadhav2, Ajinkya Bhosale3, Swapnil Yemle4, Nilesh Jadhav5
1, 2, 3, 4 U.G. Student
(B.E), Department of Mechanical Engineering, Anantrao Pawar College of Engineering &
Research, Pune, Maharashtra, India
5Assistant Professor, Department of Mechanical Engineering, Anantrao Pawar College of Engineering & Research,
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Abstract - An axle beam is a central shaft for rotating must be resistant to tolerate additional stress and loads.
wheel. Front axle carries the weight of the front part of The axles must additionally bear the weight of the vehicle
automobile as well facilitates steering and absorb shock due plus any cargo. A misaligned front axle may result in
to road surface variations. So, proper design and improper turning of tires, reduced tire life, difficulty in
optimization of front axle is extremely crucial to improve driving and unsafe vehicle. The present research work
strength to weight ratio. The paper focuses on design, deals with design of optimized front axle for heavy
analysis and optimization of front axle. The approach in this commercial vehicles. The cross-section areas and materials
research paper has been divided into two steps. The First in different models are varied by adopting the analytical
step involves design of front axle by Analytical method. For method. An existing front axle is modified for the given
this, the vehicle specification gross weight and payload load condition. Further, actual deflection occurring in
capacity is used to determine the stress and deflection in the existing axle is studied and modified front axle with
beam. Second step involved further modeling of front axle different materials and cross sectional areas is designed
using CATIA-V5 and ANSYS software. For model accordingly. The main objective of present research is to
optimization, FEA results were compared with analytical provide safe working conditions, effective stress
design. concentration, optimum weight and cost reduction for
front axle in heavy commercial vehicles.
Key Words: Front axle beam, Analytical Design,
Modeling Catia, Analysis and optimization ANSYS. 2. CONSTRUCTION AND OPERATION
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1418
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
2.1.1 Function of Front Axle hole and holds the kingpin in place in the axle. The steering
knuckle is made with a yoke at one end and a spindle at the
Front wheels of the vehicles are mounted on front axles. opposite end. Bronze bushings are pressed into the upper
Functions of front axle are listed below: and lower arms of the yoke, through which the kingpin
a) It supports the weight of front part of the vehicle. passes.
b) It facilitates steering.
c) It absorbs shocks which are transmitted due to
road surface irregularities.
d) It absorbs torque applied on it due to braking of
vehicle.
Live front Axle: Fig 2: Front axle beam linkage assembly with steering
Live axle is used to transmit power from gear box to front system
wheels. Live front axle although resemble rear axles but
they are different at the ends where wheels are mounted. These bushings provide replaceable bearing surfaces. A
Maruti-800 has live front axle. lubrication fitting and a drilled passage provide a method
of forcing grease onto the bearing surfaces of the bronze
2.2 Construction and Assembly bushings. The spindle is a highly machined, tapered, round
shaft that has mounting surfaces for the inner and outer
The front axle beam will have I cross section in the middle wheel bearings. The outer end of the spindle is threaded.
and circular or elliptical cross sections at the ends. An axle These threads are used for installing a nut to secure the
is usually a forged component for which a higher strength wheel bearings in position. A flange is located between the
to weight ratio is desirable. The I-cross section has lower spindle and yoke. It has drilled holes around its outer edge.
section modulus and hence gives better performance with This flange provides a mounting surface for the brake
lower weight. This type of construction produces an axle drum backing plate and brake components. The kingpin
that is lightweight and yet has great strength. The I-beam acts like the pin of a door hinge as it connects the steering
axle is shaped so that the center part is several inches knuckles to the ends of the axle I-beam. The kingpin passes
below the ends. This permits the body of the vehicle to be through the upper arm of the knuckle yoke, through the
mounted lower than it could be if the axle were straight. A end of the I-beam and a thrust bearing, and then through
vehicle body that is closer to the road has a lower center of the lower arm of the knuckle yoke. The kingpin retaining
gravity and holds the road better. On the top of the axle, bolt locks the pin in position. The ball-type thrust bearing
the springs are mounted on flat, smooth surfaces or pads. is installed between the I-beam and lower arm of the
The mounting surfaces are called spring seats and usually knuckle yoke so that the end of the I-beam rests upon the
have five holes. The four holes on the outer edge of the bearing. This provides a ball bearing for the knuckle to
mounting surface are for the U bolts which hold the spring pivot on as it supports the vehicle's weight. When the
and axle together. The center hole provides an anchor vehicle is not in motion, the only job that the axle has to do
point for the center bolt of the spring. The head of the is hold the wheels in proper alignment and support part of
center bolt, seated in the center hole in the mounting the weight. When the vehicle goes into motion, the axle
surface, ensures proper alignment of the axle with the receives the twisting stresses of driving and braking. When
vehicle frame. A hole is located in each end of the I-beam the vehicle operator applies the brakes, the brake shoes
section. It is bored at a slight angle and provides a are pressed against the moving wheel drum. When the
mounting point for the steering knuckle or kingpin. A small brakes are applied suddenly, the axle twists against the
hole is drilled from front to rear at a right angle to the springs and actually twists out of its normal upright
steering knuckle pinhole. It enters the larger kingpin hole position. In addition to twisting during braking, the front
very slightly. The kingpin retaining bolt is located in this axle also moves up and down as the wheels move over
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1419
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
rough surfaces. Steering controls and linkages provide the Sample model of I section
means of turning the steering knuckles to steer the vehicle.
As the vehicle makes a turn while moving, a side thrust is
received at the wheels and transferred to the axle and
springs. These forces act on the axle from many different
directions. You can see, therefore, that the axle has to be
quite rugged to keep all parts in proper alignment.
3. ANALYTICAL DESIGN
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1420
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1421
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
Chemical Compositions
1) C: 0.15 - 0.20%
2) Fe: 98.8 99.25% Fig 6: Max. Principle stress result for AISI1020
3) Mn: 0.6 - 0.9%
4) P: 0 - 0.040% Total deflection
5) S: 0 - 0.050%
Fig 4: Max. Principle stress result for SAE1018 Fig 8: Max. Principle stress result for cast iron
Fig 5: Deflection of axle for SAE1018 Fig 9: Deflection of axle for ductile cast iron
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1422
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
( ) 21.46 37.12
( ) 21.46 37.712
Total deflection From the above table 5, it is clear that maximum deflection
in axle for SAE-AISI 1018 is 4.84mm and is less as
compared to other materials. The maximum stress
distribution is low and within stress yield limit. So SAE-
AISI 1018 material is better for manufacturing of axle
beam than other materials.
5. CONCLUSION
The static strength and dynamic characteristics are
analyzed by ANSYS software. Analytical results confirm the
modified design. By comparing analytical with FEA result,
Fig 11: Deflection of axle for SAE4130 combine use of model no.1 and SAE1018 material gives
best result and helps to avoid expensive and time
Table 4: Analysis overview table consuming development loops. Moreover, it also allows the
number of high-cost test carriers to be substantially
Analysis type Static Structural reduced. This results in shortening of design period. Finally
a safe and validate design has been developed to fulfill the
No. of nodes 17137 requirement.
No. of elements 9668
Type 3D 6. REFERENCES
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1423
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
[4] Varun Ahuja, Sandip Hazra (Maruti Suzuki) [6] Pokorny, P., Nahlik, L, Hutar, P. Comparosion of
Application of Optimization Techniques in reducing different load spectra on residual fatigue lifetime of
the Weight of engine Mounting Bracket, HTC 2012 railway axle, Procedia engineering 74(2014) 313-316
[5] Javad Tarighi, Seyed Saeid Mohtasebi, Reza Alimardani [7] Maheshwari N Patil, Shreepad Sarange Finite
Static and dynamic analysis of front axle housing of Element analysis of Von Mises Stresses & Deformation
tractor using finite element analysis methods, at Tip of Cutting Tool, International Journal of
Australian Journal of Agricultural Engineering, AJAE Innovative Research in Advanced Engineering.
2(2):45-49 (2011)
BIOGRAPHIES
Kiran B. Maddewad is a student
completing Final Year of
Mechanical Engineering from
APCOER College, University of
Pune.
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1424