8/12/2019 6.SATHISH (921312408008)

1/22

Finite Element Analysis

of Cross Member Bracket of Truck

BySATHISHKUMAR . V

921312408008

Under the guidance ofMr.P. CHITHAMBARANATHAN., M.E.,

Associate Professor

8/12/2019 6.SATHISH (921312408008)

2/22

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.

8/12/2019 6.SATHISH (921312408008)

3/22

8/12/2019 6.SATHISH (921312408008)

4/22

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.

8/12/2019 6.SATHISH (921312408008)

5/22

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.

8/12/2019 6.SATHISH (921312408008)

6/22

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.

8/12/2019 6.SATHISH (921312408008)

7/22

LITERATURE SURVEY CON.

8/12/2019 6.SATHISH (921312408008)

8/22

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.

8/12/2019 6.SATHISH (921312408008)

9/22

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.

8/12/2019 6.SATHISH (921312408008)

10/22

LITERATURE SURVEY CON..

Engine mounting bracket of a car

Aeroplane engines

continental engine mounting Bracket

8/12/2019 6.SATHISH (921312408008)

11/22

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.

8/12/2019 6.SATHISH (921312408008)

12/22

SOFTWARE TOOLS

CATIA V5

Used to design truck bracket.

ANSYS 12

Used to Analysis truck bracket.

8/12/2019 6.SATHISH (921312408008)

13/22

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

8/12/2019 6.SATHISH (921312408008)

14/22

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, corrosionresistance,machining.

8/12/2019 6.SATHISH (921312408008)

15/22

BRACKET PARAMETERS

Length in mm 180

Breadth in mm 60

Height in mm 50

Thickness in mm 3

Radius of circle in mm 10

8/12/2019 6.SATHISH (921312408008)

16/22

BRACKET MODEL

8/12/2019 6.SATHISH (921312408008)

17/22

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.

8/12/2019 6.SATHISH (921312408008)

18/22

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.

8/12/2019 6.SATHISH (921312408008)

19/22

REFERENCES

[1] Zhang Junhong, Han Jun CAE process to simulate and optimise

engine noise and vibrationMechanical 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.

8/12/2019 6.SATHISH (921312408008)

20/22

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.

8/12/2019 6.SATHISH (921312408008)

21/22

REFERENCES

[8] Doo-Ho Lee,Jeong-Woo Chang,Chan-MooKim,Optimal Shape Design of an Air-Conditioner

Compressor Mounting Bracket in a Passenger Car, SAE

International, 2003-01-1667.

[9] Hong Suk Chang, AStudy on the Analysis Method for

Optimizing Mounting Brackets, SAE International, 2006-

01-1480.

[10] Mahendra M. Gaikwad, Bracket Document

112978,Coventry Engineers, UK.

8/12/2019 6.SATHISH (921312408008)

22/22

hank You