Finite Element Analysis of Truck Axle

FINITE ELEMENT
ANALYSIS OF TRUCK
AXLE UNDER VARIOUS
DRIVING CONDITIONS
[School]
[Course title]

ABSTRACT
This report targets depicting the technique for Finite Element Analysis (FEA) used to recreate an axle of a
truck. The axle is the place every one of the heaps lie upon. An axle is like a pole just that it doesn't turn.
Materials that makes these parts are subsequently solid. In this report, the cause of forces following up on
the chasses the sort of forces following up on a truck undercarriage and their places of activity on the
chasses are clarified. To have a decent view and experience with FEA components, the two axles of a
truck were structured on a CAD program (Solidworks). The Material properties of the axles, for example,
Youngs modulus, rigidity, Poisson's ratio and Yield were perused from the mass properties of the
material. With these material properties, the graphs of shear forces graphs, displacement graphs and
bending moment chart and the most extreme bending stresses (compressive stresses and tensile stresses)
were determined. The focal point of this errand is to decide the areas of the highest shear pressure,
redirection and to decide the best factor of security. In building structure FEA is a significant device in
estimation of responses, stresses, strains and deformation, which may be hard to understand by
physically. You understand that most burdens are brought about by consolidated forces and the
geometries are sporadic fit as a fiddle in this way making it hard for utilization of hand counts. This report
targets demonstrating how this issue can be handled with the assistance of FEA instruments, for example,
ANSYS. With these program utilities, a great part of the plan work is rearranged and the design engineer
is left with only a couple of things to deal with. Subsequently, production and manufacturing are
facilitated and quicker plan procedures are conceivable. They have empowered the design engineer and
creators to examine the conduct of the parts, item and structures ages before it is really delivered.
ACKNOWLEDGEMENTS
I am very thankful to my supervisors, professors who have encouraged and helped me, the library staff,
my friends, my classmates, lab assistants and lab technicians for helping me throughout this task. I really
appreciate my family and friends for always helping me and supporting me through the course of time. It
is due to their support that I am able to complete this project on time successfully.
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DECLARATION OF ORIGINALITY
I ensure that aside from where due affirmation has been made, the work is that of the creator alone; the
work has not been submitted already, in entire or to a limited extent, to meet all requirements for some
other scholastic honor; the substance of the proposition is the aftereffect of work which has been
completed since the official beginning date of the endorsed research program,; and, any publication work,
paid or unpaid, did by an outsider is recognized.
Name................................................................................................................
Date......................................................... Sign.............................................
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Contents
ABSTRACT................................................................................................................................................1
ACKNOWLEDGEMENTS.........................................................................................................................1
DECLARATION OF ORIGINALITY........................................................................................................2
LIST OF FIGURES.................................................................................................................................5
LIST OF FIGURES IN APPENDICES...................................................................................................6
Nomenclature..........................................................................................................................................6
CHAPTER 1. INTRODUCTION............................................................................................................7
OVERVIEW........................................................................................................................................7
FINITE ELEMENT ANALYSIS (FEA).............................................................................................7
OBJECTIVES......................................................................................................................................7
CHAPTER 2. LITERATURE REVIEW.................................................................................................8
CHAPTER 3: BACKGROUND THERORY ON AXLES..................................................................12
AXLES, TYPES AND CLASSIFICATION......................................................................................12
ORIGIN, ACTION AND LOCATION OF THE FORCES, LOCATION OF FORCES UNDER
VARIOUS DRIVE CONDITIONS...................................................................................................16
CHAPTER 4. METHODOLOGY.........................................................................................................18
USING CALCULATION METHOD................................................................................................18
USING FEA (SIMULATION METHOD)........................................................................................21
CHAPTER 5. RESULTS AND DISCUSSION.....................................................................................24
USING CALCULATION METHOD................................................................................................24
USING SIMULATION METHOD...................................................................................................25
FRONT AXLE..................................................................................................................................25
REAL AXLE WHEN LORRY IS MOVING ON A STRAIGHT NON-INCLINED ROAD............28
OTHER DRIVING CONDITIONS...................................................................................................31
CHAPTER 6. DISCUSSION.................................................................................................................41
CHAPTER 7. CONCLUSION AND RECOMMENDATIONS............................................................43
CONCLUSION.................................................................................................................................43
RECOMMENDATIONS FOR FURTHER WORK..........................................................................44
CHAPTER 8. BIBLIOGRAPHY...........................................................................................................45
REFERENCES......................................................................................................................................45
APPENDICES.......................................................................................................................................48
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APPENDIX A: STRESSES AND DEFORMATION CALCULATION OF FRONT AND REAR
AXLES..............................................................................................................................................48
1. FRONT AXLE..............................................................................................................................48
REAR AXLE.....................................................................................................................................54
APPENDIX B: MASS AND SECTION PROPERTIES OF FRONT AND REAR AXIS.................61
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LIST OF FIGURES
Figure 1. Fatigue life cycle of truck axle according to Hemant (2016)........................................................6
Figure 2.Yimin axle loading configuration..................................................................................................7
Figure 3. Yimin Analysis results.................................................................................................................7
Figure 4. Zhang stress concentration (Zhang 2016).....................................................................................8
Figure 5. Semi- floating axle.......................................................................................................................9
Figure 6. Full floating axle........................................................................................................................10
Figure 7.three-quarter floating axle...........................................................................................................10
Figure 8. Truck front axle..........................................................................................................................11
Figure 9. Different types of stub axle........................................................................................................12
Figure 10. Truck loading under normal conditions, (straight roads)..........................................................13
Figure 11. Truck loading during cornering................................................................................................14
Figure 12. Truck model (FUSO Canter 515 City Cab 6 Sp) on online calculator......................................16
Figure 13. Loading configuration for front axle........................................................................................17
Figure 14. Loading configuration for rear axle..........................................................................................18
Figure 15. Meshed front axle model..........................................................................................................19
Figure 16. Meshed model for real axis......................................................................................................20
Figure 17. Front Axis Minimum Principal Stress......................................................................................22
Figure 18. Maximum Principal Stress.......................................................................................................23
Figure 19. front axis Equivalent Stress......................................................................................................23
Figure 20. Front axis Maximum Shear stress.............................................................................................24
Figure 21. Front axis Total deformation....................................................................................................25
Figure 22. Rear axle Minimum Principal Stress........................................................................................25
Figure 23. Rear axle Maximum Principal Stress........................................................................................26
Figure 24. Rear axle Equivalent Stress......................................................................................................26
Figure 25. Rear axle Maximum Shear stress.............................................................................................27
Figure 26. Rear axle Total deformation.....................................................................................................28
Figure 27. Rear axle loading configuration when turning..........................................................................28
Figure 28. Rear axle when turning Von Mises Stresses.............................................................................29
Figure 29. Rear axle when turning Total deformation...............................................................................29
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LIST OF FIGURES IN APPENDICES
Figure 30. Front axle loading configuration
Figure 31.Front axle shear force diagram and bending moment diagram)
Figure 32.Front axis load, slope and deflection diagrams)
Figure 33. Rear axle loading configuration
Figure 34. Rear axle shear force diagram and bending moment diagram)
Figure 35. Rear axle load, slope and deflection diagrams)
Nomenclature
kN kilo-Newton. 1000 Newtons.
Pa Pascal. A unit of measurement of stress and pressure. 1 pascal is equal to 1 N/m2
I Inertia. (m4)
Ixx Moment of inertia in the X-X plane.
Iyy Moment of inertia in the Y-Y plane.
Izz, Moment of inertia in the Z-Z plane.
Ϭmax Maximum stresses (Compressive or tensile).
V Shear Force (kN).
M, Bending Moment (kN/m).
R. Reaction force (kN).
D Diameter.
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CHAPTER 1. INTRODUCTION
OVERVIEW
In the global market, the world demands an optimum design of a vehicle with long life of components
such as the axles, suspensions, chases and other structural parts of the vehicles. The market also demands
vehicle parts that are light, low cost but highly efficient. With regards to transportation of mass and
substantial loads by roads, trucks are broadly utilized. For such reasons, the structure of the truck axles
should be precisely solid-robust and efficient. Truck manufacturers hence need to accentuate on the
quality attributes of the trucks’ axle design beginning from the determination of the most suitable chases
and axle material to working for off-road and other harsh environment.
Likewise, the manufacturers also need to foreordain and have an idea of what might be the greatest stress
limit with regards to the axle before making the pivot to maintain a strategic distance from additional
costs that would happen if an off-base hub is created. Seeing such pivot attributes and highlights calls for
pressure investigation of the axles.
FINITE ELEMENT ANALYSIS (FEA)
FEA has turned out to be generally utilized and all around acknowledged in numerous automotive parts.
FEA is an incredible system, ready to create answers for testing auxiliary examination issues. The
innovation and computational productivity of the strategy, together with the fast increments in computer
handling capabilities implies that today the degree and size of reproductions far surpasses the abilities of
even a couple of years ago.
(FEA) is an automated technique for investigating how a parts and assemblies responds to various forces,
heat, fluid flow, vibration, and other physical conditions. It tells the design engineer whether a system
will wear out, break, or work the manner in which it was built. (Autodesk 2019).
OBJECTIVES
This paper aims at meeting the following objectives.
a) To review various types of truck axles.
b) To calculate stresses and deformation of a truck axle.
c) To do a FEA stress analysis simulation on a truck axle under different drive conditions.
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