SHAPE OPTIMIZATION OF A HEAVYDUTY TRUCK CHASSIS FRAME USING CAE TOOLS

Abstract

Weight plays a crucial role in automobile engines, significantly influencing riding qualities and travel cost. The chassis frame provides about twenty percent of the truck’s curb weight, making it a vital component in automobiles. Serving as the backbone of heavy vehicles, the chassis bears the maximum load for all operating conditions while providing a sturdy platform to connect the front and rear suspensions with minimal deflection. Consequently, both weight and strength are key parameters in chassis design. Extensive analysis of various research studies reveals opportunities for optimizing various parameters such as mass, stress-strain values, and deformations by adjusting the cross-sections of the chassis. Present work focuses on modeling, structural analysis, and heavy weight vehicle chassis optimization, considering the constraints like maximum stress and deformations at real maximum load. To conduct the study, we utilized the dimensions and material of the TATA 2518TC chassis frame for structural analysis. We considered three different cross-sections—C, I, and Hollow Rectangular (Box) types—using structural steel ST37 due to its known properties and availability. Next, we subjected these cross-sections to identical conditions and developed three-dimensional solid models using CAE software. Performing the analysis in ANSYS Workbench, we validated the results by employing analytical calculations involving shear force, bending moment diagrams, and stress distribution. Furthermore, standard optimization techniques are employed in Design Explorer, and Design of Experiments is used to perform several samplings on the three cross sections. The optimization process aims to achieve mass reduction while maintaining stress and deformation constraints and varying thickness variables. The findings indicate that the Channel section proves to be the most suitable among the tested cross sections, boasting a high strength-to-weight ratio. It results in a remarkable 31% reduction in weight when compared to the existing TATA 2518TC chassis frame. This insight could lead to improved performance and efficiency in heavy vehicles.