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Finite Element Analysis

of Cross Member Bracket of Truck




By
SATHISHKUMAR . V
921312408008

Under the guidance of
Mr.P. CHITHAMBARANATHAN., M.E.,
Associate Professor

OBJECTIVE OF THE PROJECT WORK
The component bracket in the cross member of chassis is one the
most important parts of heavy trucks.
Rear ones bear payloads and the front one has to bear the
engine and transmission. For suspension, handling , body
alignment, etc. they need to be strong , besides being
complicated, costly and time consuming to replace, if damaged.
Stresses induced lead to the failure of the component brackets in
the cross members.
OBJECTIVE OF THE PROJECT WORK
This study aims to investigate the critical points of stresses
that lead to induce failure.
To analyze, finite element method (FEM) is used &
commercially available packages CATIA V5 and ANSYS
12 are used for modeling and stress analysis.
Modifications have been made to current bracket & these
modifications have resulted in reduction in stress values .
SCOPE OF THE PROJECT WORK

Modifications have been made to current bracket &
these modifications have resulted in reduction of
stress values leading to safe design.

LITERATURE SURVEY
Balbirsingh R. Guron1, Dr. D.V. Bhope2, Prof. Y. L.
Yenarkar3 Finite Element Analysis of Cross Member
Bracket of Truck Chassis. In earlier models of trucks, the
cross members were of single piece design and now comes as a
multicomponent part. The cross member component nearest to
the chassis (bracket) has to bear the brunt of all the loading and
ultimately develops fractures starting at the rivet holes.
LITERATURE SURVEY CON.
This implies that, though the rivets hold the part well, the
load ultimately leads to development of cracks in the
member. Observation, questionairring and survey of fleets
revealed that, this bracket situated nearest to the chassis
mainframe is the biggest downtime contributor & the failure
of the bracket is observed at the rivet holes.


LITERATURE SURVEY CON.


LITERATURE SURVEY CON..
UMESH S. GHORPADE1, D. S. CHAVAN2, VINAAY PATIL3 &
MAHENDRA GAIKWAD4. FINITE ELEMENT ANALYSIS
AND NATURAL FREQUENCY OPTIMIZATION OF
ENGINE BRACKET. Engine is one of the most
important components of a road vehicle such as car.
High performance sport car has their engine supported
by bracket. It plays an important role in improving the
comfort & work environment of a car.
LITERATURE SURVEY CON..
The improvement of engine bracket system has
been the subject of intense interest for many years. It is
necessary to design proper engine bracket for a car. As
such, engine bracket has been designed as a framework to
support engine. Vibrations and fatigue of engine bracket
has been continuously a concern which may lead to
structural failure if the resulting vibrations and stresses are
severe and excessive. Prolonged exposure to whole-body
vibration in the working environment may lead to fatigue
and in some cases it damages the car.
LITERATURE SURVEY CON..
Engine mounting bracket of a car
Aeroplane engines
continental engine mounting Bracket

METHODOLOGY

The aim is to identify the cause of failure of the cross
member bracket and to suggest design changes.
The failure analysis of the cross member bracket is effected
by design and analysis approach.
The failure analysis has been carried out using standard FE
tools. The material is selected existing stainless steel and
aluminium alloy and comparing both results.



SOFTWARE TOOLS
CATIA V5
Used to design truck bracket.
ANSYS 12
Used to Analysis truck bracket.

Stainless steel
Austenite stainless steel
Grades 301,301L,301LS,304,304L,304H high strength for roll
formed structural.
Ferritic stainless steel
Atlas CR12,CR12Ti, steel resistant
Duplex stainless steel
2101,2304 economical alternative
Martensitic stainless steel
410,416 bar grade
Precipitation hardening stainless steel
630 high strength shafting grade


Aluminium grade
2011-T4,5083-H112,6061-T6,7075-T6 grade
&tempering :min&max chemical composition
AL%,si%,fe% cu,mn,mg,cr,zn,ti,others material
thickness in mm mchanical properties calculate
tensile strength, yield strength, elongation, corrosion
resistance,machining.

BRACKET PARAMETERS
Length in mm 180
Breadth in mm 60
Height in mm 50
Thickness in mm 3
Radius of circle in mm 10
BRACKET MODEL
CONCLUSION
This study aim is to investigate the critical points of
stresses that leads induce failure. The investigation of
bracket is fully studied. To finding the stress on
bracket, holes are identified. The material selection is
stainless steel and aluminum alloy. It is used to design
and analyzing the bracket. Modifications have been
made to current bracket & these modifications have
resulted in reduction of stress values.
FEATURE WORK OF THE PROJECT
Modifications have been made to current bracket & these
modifications have resulted in reduction in stress values
leading to safe design.
CATIA V5 software used to design bracket and design
modifications.
ANSYS 12 software used to analysis the bracket.
And also determine the stress and deformation of the
bracket. The material selection is stainless steel and
aluminium alloy and comparing both results.

REFERENCES
[1] Zhang Junhong, Han Jun CAE process to simulate and optimise
engine noise and vibration Mechanical Systems and Signal Processing
20 (2006) 14001409.
[2] Gabriel-Petru ANTON, Mihai PAVAL, Fabien
SOREL,APPLICATION ON AN UPDATED FINITE ELEMENT
MODEL OF AN ENGINE IN THE AUTOMOTIVE INDUSTRY
SISOM 2011 and Session of the Commission of Acoustics, Bucharest
25-26 May.
[3] Senthilnathan Subbiah, O.P. Singh, Effect of muffler mounting
bracket designs on durability, Engineering Failure Analysis 18 (2011)
10941107.
REFERENCES
[4] Youngwoo Choia, Dohyun Jungb, Kyoungchun Hamc,
A study on the accelerated vibration endurance tests for
battery fixing bracket in electrically driven vehicles,
Procedia Engineering 10 (2011) 851856.
[5] S.K. Loh a, W.M. Chin a, Waleed F. Faris, Fatigue
analysis of Package Terminal Air Conditioner motor bracket
under dynamic loading, Materials and Design 30 (2009)
32063216.
REFERENCES
[8] Doo-Ho Lee,Jeong-Woo Chang,Chan-Moo
Kim,Optimal Shape Design of an Air-Conditioner
Compressor Mounting Bracket in a Passenger Car, SAE
International, 2003-01-1667.
[9] Hong Suk Chang, A Study on the Analysis Method for
Optimizing Mounting Brackets, SAE International, 2006-
01-1480.
[10] Mahendra M. Gaikwad, Bracket Document
112978,Coventry Engineers, UK.