PROJECT ON DESIGN AND

ANALYSIS OF CHASSIS
 ABSTRACT

• Chassis is the French word was used to denote the frame parts or main structure of the vehicle. In automobile the word
chassis frame means the part of automobile that hold all the important parts of vehicle like engine, steering systems,
suspension system, and all the components constitute together to form a chassis and also, it has to withstand the shock,
twist, vibration and other stresses caused due to sudden breaking, acceleration, shocking road condition, centrifugal force
while cornering and forces induced by its components. The chassis acts as the backbone of the vehicle which caries the
maximum load for all designed operating conditions. It is usually made up of steel frame.
The present study has analyzed the various literatures. After a careful analysis of various research studies conducted so far it
has been found that there is the scope of optimizing different factors like weight, stress-strain values and deformation etc.
by varying cross sections for modeling and analysis this paper describes the design and structural analysis of the vehicle
chassis with constraints of maximum stress, strain and deflection of chassis under maximum load.
• In the present work own design and dimensions chassis is used for the structural analysis of the vehicle chassis by
considering three different cross sections, namely C, I and hallow rectangular type cross sections with different materials
(like steel, epoxy, graphene) subjected to the same conditions. A three dimensional solid in the CAE software CATIA and
analyzed in ANSYS and by using the composite material like graphene, steel, and glass epoxy. The numerical results are
validated with analytical calculation considering stress distribution and deformation for our model.
• KEYWORDS: vehicle chassis frame, CATIA, ANSYS, FEM, assembly weight, stress, deformation, composite material like
graphene, steel, glass epoxy.
 INTRODUCTION
 
• Many types of pollution such as water pollution, noise pollution, thermal pollution and air
pollution. Air pollution can be considered as one of the main hazard to the health of
human being. The air pollution is due to the increasing number of vehicle use by human.
When the number of vehicle increase, the usage of the petrol increase respectively. The
lack of the source of the petrol makes the price increase by time to time. The emission
from the vehicle makes the environment faces the air pollution that in critical level.
• Many steps need to reduce the number of the vehicle in other side to reduce the price of
the petrol. Besides that also use to reduce the air pollution. The big number of vehicles in
each country makes the prevention to reduce the number of vehicle difficult. So, the
other prevention is increase the efficiency of the vehicle’s engine. When the engine at the
efficient level, the emission is at the low level and the most important is the usage of
petrol is low. The prevention is reducing the weight of the body and chassis of each
vehicle.
• This project focused to reduce the usage of petrol by design and analysis the chassis to
reduce the weight of the chassis of vehicle. At the same time, the global usage of the
petrol also reduced.
 LITERATURE REVIEW
 
• Basically chassis is considered as a framework to support the body,
engine and other parts which make up the vehicle. Chassis lends the
whole vehicle support and rigidity. Chassis usually includes a pair of
longitudinally extending channels and multiple transverse cross
members that intersect the channels. The transverse members have
a reduced cross section in order to allow for a longitudinally
extending storage space. The chassis has to contain the various
components required for the race car as well as being based around
a driver’s cockpit. The safety of the chassis is a major aspect in the
design, and should be considered through all stages. Generally, the
basic chassis types consist of backbone, ladder, spaceframe and
monocoque. Different types of chassis design result the different
performance.
 PROJECT OVERVIEW
• . Objective of the project:
•  
• Modelling of Chassis using existing specifications.
• Obtaining design of Chassis using CATIAV5 software and
then imported into ANSYS 15.0 workbench
• Meshing of design model using ANSYS 15.0.
• Analysis of Chassis by using static structural analysis
• Identification of the suitable material for manufacturing
of the Chassis under specified conditions. Conclude the
suitable material based on stress, deformation values.
. Design process of a Chassis
NON-LINEAR STATIC ANALYSIS OF AN CHASSIS
• . Tasks to be done ANSYS:
• 1. Each part in the Chassis component has to be capable
of holding both tensile and compressive loads
successively.
• 2. Stresses and deflection should be within the
permissible limits.
• 3. Perfect contact pair should be formulated.
• 4. Parts of the component should always be bonded to
each other.
• 5. Converges of the model should be achieved.
• Boundary Conditions:
 Figure 6.1 Von-mises stress Figure 6.2 Equivalent strain

RESULTS AND DISCUSSIONS

• Static Analysis
• 6.1 Chassis Rectangular cross section Normal Design: We observe Von-Mises stress and Von-
Mises strain and Total deformation for material under 3 types of loading conditions.
• BOX TYPE STRUCTURE WITH NORMAL DESIGN
• TOP LOADING CONDITION:

• 6.1.1a Steel material

• Figure 6.1 Von-mises stress Figure 6.2 Equivalent strain
 6.1.1b Glass Epoxy material

• Figure 6.3 Total deformation

• Figure 6.6 Total deformation

• 6.1.1b Glass Epoxy material

• Figure 6.4 Von-mises stress Figure 6.5 Equivalent strain
 Figure 6.9 Total deformation

• 6.1.1c Graphine material

• Figure 6.7 Von-mises stress Figure 6.8 Equivalent strain

Figure 6.9 Total deformation

• 6.2 Chassis I cross section Normal Design
• Top load condition
• 6.2.1a Steel material
• Figure 6.28 Von-mises stress Figure 6.29 Equivalent strain

•
• Figure 6.30 Total deformation

•
• 6.2.1b Glass Epoxy material
• Figure 6.31 Von-mises stress Figure 6.32 Equivalent strain

• Figure 6.33 Total deformation

•
• 6.2.1c Graphine material
• Figure 6.34 Von-mises stress Figure 6.35 Equivalent strain

Figure 6.36 Total deformation

 Figure 6.57 Total deformation

• 6.3 Chassis Rectangular cross section X_Design: We observe Von-Mises stress and Von-Mises
strain and Total deformation for material under 3 types of loading conditions.
• Top load condition
• 6.3.1a Steel material
• Figure 6.55 Von-mises stress Figure 6.56 Equivalent strain

• Figure 6.57 Total deformation

•
• 6.3.1b Glass Epoxy material
• Figure 6.58 Von-mises stress Figure 6.59 Equivalent strain

• Figure 6.60 Total deformation

• 6.3.1c Graphine material
• Figure 6.61 Von-mises stress Figure 6.62 Equivalent strain

•
• Figure 6.63 Total deformation
• 6.4 Chassis I cross section X_Design
• Top load condition
• 6.4.1a Steel material
• Figure 6.82 Von-mises stress Figure 6.83 Equivalent strain

• Figure 6.84 Total deformation

• 6.4.1b Glass Epoxy material
• Figure 6.85 Von-mises stress Figure 6.86 Equivalent strain

• Figure 6.87 Total deformation

• 6.4.1c Graphine material
• Figure 6.88 Von-mises stress Figure 6.89 Equivalent strain

• Figure 6.90 Total deformation

 Table 6.2 I Structure With Normal Design

Frontal Crash Side Impact Axial Loading

Total Total Total
Stress(MPa) Strain Stress(MPa) Strain Stress(MPa) Strain
Deformation(mm) Deformation(mm) Deformation(mm)

Steel 30.971 0.00042 0.469 23.767 0.00037 0.0278 3.562 5.46E-05 0.0009
E-Glass Epoxy 32.3 0.0032 3.4 23.79 0.00023 0.194 3.61 0.00037 0.0601
Graphine 30.79 0.00015 0.1734 22.46 0.00013 0.0101 3.44 2.05E-05 0.00033

Table 6.1 Box Structure With Normal Design

Frontal Crash Side Impact Axial Loading

Total Total Total
Stress(MPa) Strain Stress(MPa) Strain Stress(MPa) Strain
Deformation(mm) Deformation(mm) Deformation(mm)
Steel 17.41 0.000241 0.31 7.605 0.0001 0.0097 1.217 1.99E-05 0.000198

E-Glass Epoxy 17.67 0.0017 2.25 8.0662 0.00081 0.07 1.22 0.000125 0.001319
Graphine 17.4 8.84E-05 0.113 7.56 3.85E-05 0.00356 1.171 7.41E-06 0.000073

fig.Structure with normal

design
 Frontal Crash Side Impact Axial Loading
Total Total Total
Stress(MPa) Strain Stress(MPa) Strain Stress(MPa) Strain
Deformation(mm) Deformation(mm) Deformation(mm)
Steel 30.88 0.00042 0.464 20.456 0.00042 0.0199 3.71 5.20E-05 0.00092

E-Glass Epoxy 32.17 0.00322 3.36 20.463 0.00027 0.138 3.76 0.0004 0.0608
Graphine 30.708 0.000155 0.169 19.426 0.000157 0.0073 3.703 2.13E-05 0.000337

Table 6.3 Box Structure With X Design

Frontal Crash Side Impact Axial Loading

Total Total Total
Stress(MPa) Strain Stress(MPa) Strain Stress(MPa) Strain
Deformation(mm) Deformation(mm) Deformation(mm)
Steel 17.385 0.000241 0.31 8.624 0.00012 0.009 1.23 2.00E-05 0.000203

E-Glass Epoxy 17.417 0.0017 2.25 8.962 0.00091 0.064 1.265 0.000132 0.00137
Graphine 17.053 8.83E-05 0.113 8.5809 4.30E-05 0.0033 1.165 7.70E-06 0.00007

Table 6.2 I Structure With X Design

• Graphs
 conclusion

• The static structural analysis of the Chassis has a great significance, In this project, the design approach for a Chassis using
CATIA V5 R20 software, Analysis work was supported by ANSYS 15.0
• Static structural analysis are to be performed. Among the Static structural analysis considered on materials and designs.
• In this project we observed 3 type loading conditions results
• Steel Material exhibited the maximum stress of 30.97 MPa and Total deformation of 0.469mm at maximum load applied.
• E glass Epoxy Material exhibited the maximum stress of 32.3 MPa and Total deformation of 3.4 mm at maximum load
applied.
• Graphene Material exhibited the maximum stress of 30.7 MPa and Total deformation of 0.173mm at maximum load
applied.
• From the Analysis results Graphene Material produces less stress compare to other two materials, and the use of Graphene
material we reduce weight of chassis and increase efficiency. Finally we conclude that Graphene is better material suitable
for Chassis.
• Future scope of the work
• There are several areas where further work clearly needs to be done.
• 1. Further designs should be directed toward Chassis life time estimation.
• 2. Further work can be carried out for dynamic analysis.
 Referances

• BOOKS
• HERB ADAMS," CHASSIS ENGINEERING”.
• R. Rajput, “Strength of materials”.
• V.B. Bhandari K.
• “Design of Machine Elements”.

• JOURNAL PAPERS,
• A.Hari Kumar, V.Deepanjali, “Design &Analysis Of Automobile Chassis”,International Journal Of Engineering
Science And Innovative Technology (Ijesit),Volume 5, Issue 1, January 2016, Issn: 2319-5967.
• Abhinay Nilawar, Harmeet Singh Nannade, Amey Pohankar, Nikhil Selokar,
• “DESIGN OF GO-KART”, Maharashtra,India, IJFEAT, ISSN: 2321-8134.
• Koustubh Hajare, Yuvraj Shet, Ankush Khot, “A Review Paper On Design And Analysis Of A Go-Kart Chassis”, IJETMAS,
Volume 4, ISSUE 2, ISSN 2349 - 4476, February 2016.
• Rahul Thavai, Quazi Shahezad, Mirza Shahrukh, Mukri Arman, Khan Imran, “STATIC ANALYSIS OF GO-KART CHASSIS BY
ANALYTICAL AND SOLID WORKS SIMULATION”, IJMER, ISSN: 2249– 6645 , Vol. 5 ,Issue 4, Apr. 2015.
• Shaik Himam Saheb, Govardhana Reddy, Md. Hameed ‘DESIGN REPORT OF A GO KART VEHICLE’ International Journal of
Engineering Applied Sciences and Technology, Vol. 1, Issue 9, ISSN No. 2455-2143, Pages 95-102, 2016.
• Sannake Aniket S.,Shaikh Sameer R., Khandare Shubham A., Prof. S.A.Nehatrao, “Design and Analysis of Go-kart Chassis”
IJARIIE-ISSN(O)-2395-4396, Volume 3, Issue 2, 2017.
• Koustubh Hajare, Yuvraj Shet, Ankush Khot, “A Review Paper on Design and Analysis of a Go-Kart Chassis” International
Journal of Engineering Technology, Management and Applied Sciences, ISSN 2349-4476, Volume 4, Issue 2, Feb 2016