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# Finite Element Analysis for stress calculations and safety

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### Finite Element Analysis for stress calculations and safety

1. 1. M.E. Seminar 3 Harshal R. Borole Finite Element Analysis Techniques for Stress Calculations and safety of Dump Truck Frame
2. 2. Introduction Nowadays, transportation industry plays a major role in the economy of modern industrialized and developing countries. The goods and materials carried through heavy trucks are dramatically increasing.  There are many aspects to consider when designing a heavy trucks chassis, including component packaging, material selection, strength, stiffness and weight. A dump truck frame is the most crucial part of the truck that gives strength and stability to the vehicle under different conditions. A dumper frame – rigid to withstand shock, twist, vibration and other stresses. A well structured and properly built frame improves crash worthiness, passenger safety and weight efficiency
3. 3. Significance of the dumper frame Dump truck is the variant on the basis of chassis, mainly consisted of the chassis, power transmission device, lifting mechanism, sub-frame, special-purpose box and back flip axis etc. The sub-frame plays the role of transitional frame to enable the main frame support as much homogeneous load as possible. Sub-frame is connected to main frame through u-shape bolts and thrust connection board, and is hinged with cargo body through the back flip axis and lifting cylinder. Frame is subjected to various loads at different conditions.
4. 4. A 3D model of various mountings on the dump truck frame during unloading process
5. 5. Dump Truck Frame A Dumper truck frame is a complex assembly which supports the loads from lifting cylinder and carriage and also is subjected to harsh, uneven road conditions. The frame should have optimum strength along with adequate bending and torsional stiffness to withstand such loads and conditions. FEA study provides the basis for designing the frame since the frame is modeled in various CAD softwares and analysis for strength and bending is done by applying boundary conditions and different loads. Different researchers have used different analysis techniques for optimizing the design of frame for strength and weight reduction.
6. 6. AGENDA Statement of Purpose Design Considerations FEA Techniques Modeling and Analysis Results & Discussions
7. 7. Statement of Purpose To Study various finite element analysis techniques used for a) Calculating different types of stresses induced and deformation of dump truck frame subjected to various loading conditions. b) Determining the critical areas of stress concentration for a fail-safe and lightweight structure.
8. 8. Design Considerations The dumper frame is very critical in designing as there are various factors to be considered while a) Dumper frame at rest – Static loads supported by the frame. b) Dumper is moving - different sets of vibration modes of the frame. c) Dumper is unloading – Dynamic loads and torque reactions.  For the first case, FEA is done on different sections of the frame for determining the critical areas of stress concentration.  For second case, FEA is done on the whole frame which is excited to different low frequencies which are close to potential exciting sources like oscillations of
9. 9. Finite Element Analysis Techniques Based on the conditions, dumper truck frame is analyzed for stress optimization by following techniques : 1) FEA for Static load. 2) Modal analysis for determining various mode shapes and predicting different dynamic responses under excitations. 3) Dynamic analysis of the frame structure during initial state of cylinder lifting and critical state of goods declining. 4) FEA by reinforcement technique for stress optimization.
10. 10. Static Load Analysis  For this analysis, a standard dump truck with following specifications was used and the frame model was prepared in CATIA and finally analyzed with the help of ANSYS software.  Gross Vehicle Weight (GVW): 25000kg.  Gross Combined Weight (GVW + Payload): 26200kg.  Frame: Ladder type heavy duty frame, depth- 285mm, width- 65mm, frame width- 903mm.  The magnitude of pressure on the upper side of chassis is determined by dividing it into 3 parts. 1) P1= F/A = 128511 / 65 * 10-6 * 6670 = 290321.9248 N/m2 2) P2 = 1200 * 9.81 / 65 * 10-6 * 1400 = 129362.6374 N/m2 3) P3 = 1200 *9.81 / 65 * 10-6 * 740 = 244740.1247 N/m2
11. 11. Total Deformation of frame by static analysis
12. 12. Modal Analysis Of Truck Frame  Frame forms the backbone of the dump truck, when the truck travels along the road, the truck chassis is excited by dynamic forces caused by the road roughness, engine, transmission etc.  After constructing a finite element model for the frame, modal analysis can be used a tool to determine natural frequencies and mode shapes.