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Dump Truck Static Analysis PDF
Dump Truck Static Analysis PDF
CHAPTER 3
3.1 INTRODUCTION
The chassis forms the backbone of the dump truck and its chief
function is to safely carry the maximum load, whether the vehicle is in static
or dynamic condition. There are some advantages of off-road vehicles chassis
over other chassis. It suffers from some major disadvantages like heavy
weight, fatigue failure and welding cracks. With the help of simulation tools
like finite element method, the extent of the effects of chassis input conditions
can easily be estimated with minimum experimental cost. As a test study, a
3-D finite element model was developed to predict the complete static stresses
and fatigue life of the high strength structural chassis, determine the stresses
on the chassis.
Dump truck is mainly used for coal application. The chassis carries
50~60 ton range of payload as shown in Figure 3.1.
The chassis forms the main structure of the dump truck and its chief
function is to safely carry the maximum load wherever the operation
demands. Basically, it must absorb engine and axle torque and absorb the
shock loads over twisting, pounding and uneven roadbeds when the vehicle
moves along the road.
front rail structure is located next to the bumper on both LH and RH side.
Horse collar, which is the portion at the middle of the chassis, carries engine
and suspension system. Rear torque tube structure which is used to join left
and right side of the rail structure is also used to withstand the load while the
vehicle is in torsion and cornering cases. The body pad is fitted on the chassis
to carry payload. Finally, rear rail structure is at the end of the chassis mainly
used for mounting rear axle and suspension of the chassis. Totally 143 parts
are assembled as per the fabricated structure.
Material Properties
Young Modulus 200GPa
Poisson Ratio 0.33
Density 7827.08kg/m3
Symmetry Linear isotropic
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GVW
Front Rear
2/3 WB 1/3 WB
WB
H = 0, V = 0, M = 0
961380 N
F R
2/3 WB 1/3 WB
WB
FRT
2/3 WB = 2707 mm
1/3 WB = 1353 mm
FRT = 640999 N
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FFT = 320381 N
FFT = 13349 N
FRT = 160250 N
F1v = 0 N
F2v = 0 N
F RT = F3V + F4V
GVW = 961380 N
RT =2920 mm
FT = 3480 mm
F2v = 320381 N
F4v = 831724 N
F3v = -671474 N
MGVM = kg Maximum Gross Machines Mass (i.e mass of vehicle itself plus payload)
98.000
MGVW = N Maximum Gross Vehicle Weight (i.e weight of vehicle itself plus payload)
961.380
MGVW1/3 = N 1/3 of the MGVW is distributed across the front axle of the vehicle
320.460
MGVW2/3 = N 2/3 of the MGVW is distributed across the rear axle of the vehicle
640.920
VF = 160.230 N 1 g vertical reaction force at one (1) Front tire patch
Vg = 320.460 N 1g vertical reaction force at one (1) Rear tire patch
1g F1V= 1×VF = N F2V = 1 × VF = N F3T = 1 × VR = N F4V = 1 × VR = N
160,230 160,230 320,460 320,460
2g F1V = 2 × vF = N F2V = 2 × VF = N F3T = 2 × VR = N F4V = 2 × VR = N
320,460 320,460 640,920 640,920
Left F1V = 0 = 0 N F2V = 2 × VF = N F3T = 0.5 × VR N F4V = 1.5 × VR N
Ramp 320,460 = 160,230 = 480,690
Right F1V = 2 × VF = N F2V = 0 = 0 N F3T = 1.5 × VR N F4V = 0.5 × VR N
Ramp 320,460 = 480,690 = 160,230
The IGS file format of the model from Pro-E has been imported
into HYPER MESH software for geometry cleanup, followed by 2D and 3D
meshing. The complete meshed model is shown in Figure 3.5.
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2D element - trias
3D element - tetra
3.5.1 2D Meshing
The 2D mesh can be carried out to the entire chassis structure using
trias mesh to get accurate results. Front rail structure and horse collar portion
has been meshed both quad and trias (mixed mesh). The purpose of 2D mesh
has been considered for creating 3D four nodded tetra mesh. 3D mesh is a
mesh, which forms a matrix method to find out the displacement and stress
distribution of the chassis. Quality check like aspect ratio warpage, Jacobian,
skew, max and min angle has been done for the entire chassis.
To improve the quality of selected elements and to satisfy the quality criteria
Quality index Set criteria for all standard quality checks simultaneously
evaluate element quality Combine all checks into a single value called
“composite quality index value” Edit nodes and elements interactively or by
automatically maximizing element quality.
The same finite element model can be used for the fatigue analysis
of the chassis, if the adequate data are available on the repetitions of the loads
creating stresses on the chassis above the endurance limit of the chassis
material. The same model can also be used to analyze the lateral vibrations
responses.
Force
Force
Force
Force
Assumption: Liner static analysis is carried out for the main frame
structure of dump truck at zero inclination. Torsion loading consists of, left
and right torsional racking conditions. Calculated reaction forces applied at
the left front (LF) and right rear (RR) suspension mounting points vertically
upward direction. Body weight and payload will be constrained at the top of
the body pad on the chassis. This is called torsional left racking condition.
shown in Figure 3.9.
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Left right front (RF) and left rear (RR) suspension mounting points
act vertically downward direction. Body weight and payload will be
constrained at the top of the body pad on the chassis. This is called torsional
right racking conditions as shown in Figure 3.10.
Force
Force
Force
Force
Bending and torsion load cases have been evaluated and the results
indicate that the vertical load case is the most critical area at the rear rail
structure of the chassis. The location of Maximum Von-misses stress
distribution occurred at the rear rail structure of the chassis, which is in
contact with the body, as shown in Figure 3.13. The stress magnitude is
noticed at critical point.
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Vertical maximum load case gives the highest stress at the position
where the side member changes the cross section height. Two of the major
cross members take much of the load from the vehicle and reaches stresses up
to 304 MPa in the rear rail structure. Some of the minor reaches stresses up to
approx 222.6 MPa, but many of them are low stressed. We also see that the
rear part of the side member is less stressed, near the horse collar and the rear
rail structure exhibits more stress on the chassis.
In finite element analysis the stress values can be more than these
values. The reason is the manufacturer requirements as a linear, elastic and
static analysis. In the static analysis, stress value is gets bigger without
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encountering any resistance. In addition the static torsion tests are processed
in a single vertical direction and axis. Reality loads can be affected different
angles. This situation makes the maximum. In the chassis analyses max. Von-
misses stresses for 12mm × 24 mm is: 304 MPa and 16mm × 25mm
222.6 MPa.
3.10 CONCLUSION