Experimental Analysis and Quasi-Static Numerical Idealization of Dynamic Stresses on a Heavy Truck Chassis Frame Assembly

The current trend in automotive design is to optimize components for weight. To achieve this, automotive designers need to have complete understanding of various stresses prevalent in different areas of the component. The chassis frame assembly of a heavy truck used for long distance goods hauling application is chosen for this investigation and dynamic stress-strain response of the component due to braking and cornering maneuvers are experimentally measured and reported. A quasi-static approach that approximates the dynamic maneuvers into number of small processes having static equilibriums is followed to carry out the numerical simulation, approximating the dynamic behavior of frame rail assembly during cornering and braking. With the help of commercial finite element package ANSYS, the quasi-static numerical simulations are carried out and compared with experimental results. This study helps in understanding prevailing stresses in truck frame rails especially during cornering and braking maneuvers and brings out all geometric locations that may be potential failure initiation locations. This study makes a case for further investigation on the effects of residual and assembly stresses on frame rails.