issn: 2454-1362, design and ... · mr. jnanesh. k d a research scholar, mechanical engineering,...

Imperial Journal of Interdisciplinary Research (IJIR) Vol-2, Issue-9, 2016 ISSN: 2454-1362, http://www.onlinejournal.in

Imperial Journal of Interdisciplinary Research (IJIR) Page 858

Design and Modal Analysis of Lower Wishbone

Suspension Arm Using FE Approach

Mr. Prashanthasamy R.M.Ta, Dr. Sathishab, Mr. Imran Ali M.Rc &

Mr. Jnanesh. K d

a Research Scholar, Mechanical Engineering, S.I.E.T, Tumkur, Karnataka, India. b H.O.D and Professor, Mechanical Engineering, S.I.E.T, Tumkur, Karnataka, India.

c Assistant Professor, Mechanical Engineering, H.M.S.I.T, Tumkur, Karnataka, India. d Research Engineer at Think and Ink Education and Research Foundation Bangalore,

Karnataka, India

Abstract: In automobile industries wishbone arm is

major component in this suspension system which

is of independent suspension. The major function of

arm is to maintain smooth suspension condition.

The arms are usually upper and lower arm. The

loads will be acting more on lower arm than upper

arm because of its position. These load conditions

on lower arm leads to maximum bending. Presently

in the most of the automobiles industries are using

suspension arm of hallow and idled of steel AISI

1040 material. Hence in this thesis the study is

made on existing design with aluminum alloy. The

3D model will be generated by Catia V5, the FE

model will be generated by HyperMesh and the

static and dynamic analysis will be conducted by

Abaqus.

INTRODUCTION

The postponement structure is a prominent

amongst the most critical segments of vehicle,

which specifically influences the wellbeing,

execution, clamor level and style of it. The vehicle

suspension framework is in charge of driving

solace and security as the rearrangement conveys

the automobile-body and transmits all powers

between corpse and street. Emphatically, with a

exact end goal to impact these properties, semi-

dynamic segments are presented, which empower

the deferral scaffold to adjust different driving

conditions. From a configuration perspective, there

are two principle classes of unsettling influences on

a truck to be definite the street and burden

aggravations.

LITERATURE SURVEY [2] This anticipate presents the

advancement of hearty configuration of lower

suspension arm utilizing stochastic improvement.

The quality of the outline examine by limited

component programming. The basic model of the

lesser postponement arm was mode by utilizing the

strong works. The imperfect component replica and

assessment were executed using the partial

constituent investigation code. The direct versatile

examination was performed utilizing NASTRAN

codes. TET10 and TET4 network has been utilized

as a part of the anxiety inspection and the most

noteworthy Von Mises anxiety of TET10 has been

chosen for the hearty design parameter.The

improvement of Powerful outline was completed

utilizing the Monte Carlo approach, which all the

streamlining parameter for the configuration has

been advanced in Strong arrangement

programming. The changes from the Stochastic

Outline Change (SDI) are acquired. The outline

capacity to bear more weight with lower

anticipated anxiety is distinguished through the

SDI procedure. A minor thickness and modulus of

versatility of material can be reexamined with a

specific end goal to streamline the delineate. [3] is

a strategy for idea choice utilizing a scoring lattice

called the Pugh Grid. It is executed by building up

an assessment group, and setting up a lattice of

estimation criteria versus elective epitomes. This is

the scoring framework which is a type of

prioritization lattice. For the most part, the choices

are attain in respect to criteria utilizing a typical

methodology (one image for superior to, another

for unbiased, and another for more regrettable than

gauge). These get changed over into achieves and

consolidated in the scaffold to yield scores for

every alternative. [7] Palma, in this study, a

disappointment investigation of a longitudinal

stringer of a model vehicle has been done.

Disappointment occurred at the guards obsession

purposes of the vehicle suspension amid toughness

tests. Break was made and has developed creating

crack of the segment. Stress investigation was

performed utilizing limited component strategy. A

support model to take care of the issue was

proposed. Test semi static and sturdiness tests were

completed and disappointments were no more

watched.

OBJECTIVES & METHODOLOGY

3.1 OBJECTIVE:

1. To prepare the existing design of

wishbone suspension arm.

http://www.onlinejournal.in/




2. To conduct linear static and dynamic

analysis for the existing design.

3. To create an optimized design by

conducting geometric material

optimization.

3.2 METHODOLOGY: 1. Existing design of the wishbone

suspension arm is studied.

2. 3d CAD model of the design will be

created.

3. FE Model of the design will be created.

4. Analysis under Static and modal

conditions will be done and the behaviour

of component will be estimated.

5. Based on the results obtained in analysis

the design will be optimized in different

stages.

6. Finalized design will be presented.

RESULTS AND DISCUSSIONS

4.1 DESIGN AND ANALYSIS OF EXISTING

WISHBONE ARM:

4.1.1 2-D DRAWING OF EXISTING

WISHBONE ARM:

Fig4.1: 2D drawing of Existing Wishbone Arm

4.1.2 3-D MODEL OF EXISTING WISHBONE

ARM: 4.2 FINITE ELEMENT MODEL OF

EXISTING WISHBONE ARM:

Fig4.2: CAD Model of Existing Wishbone Arm

Fig: 4.3 Finite Element Model Existing Wishbone

Arm

4.3 ANALYSIS WITH AISI 1040

Table: 4.1

MATERIAL PROPERTIES OF AISI 1040:

YOUNGS MODULUS 210 GPa

POISSONS RATIO 0.30

DENSITY 7.845 e-3 g/mm3

YIELD STRESS 410 MPa

BOUNDARY CONDITIONS FOR LINEAR

STATIC ANALYSIS:

One end is constrained in all the directions and

other end is applied a load of 5000 N for this

Distributed pressure is applied.

Load, F = 5000 N

Area of applied pressure, A = 7520 mm2

Therefore, Pressure, 𝑃 =Force

Area =

5000

7520= 0.664 MPa

Hence, the pressure is applied of 0.664 MPa

Fig: 4.5 Boundary Conditions

4.4 RESULTS OF LINEAR STATIC

ANALYSIS OF EXISTING DESIGN:

4.4.1 Von-Mises Stress:

4.4.2 DEFORMATION PLOT:

Fig: 4.6 Von-Mises Stress Plot

Fig: 4.7 Deformation Plot

Maximum Stress = 218.2 MPa

Maximum Deformation = 2.062 mm

4.5 MODAL ANALYSIS OF EXISTING

DESIGN FOR AISI 1040:

Deformation plots for different Natural

Frequencies:





Table: 4.2 Frequency Modes of Existing Design

Modes Frequeinces

Mode 1 0.2418

Mode 2 0.8247

Mode 3 0.9216

Mode 4 1.3160

Mode 5 2.0980

4.7 ANALYSIS WITH ALUMINIUM ALLOY

Table: 4.3 MATERIAL PROPERTIES OF

ALUMINIUM ALLOY:

YOUNGS MODULUS 68.3 GPa

POISSONS RATIO 0.33




STATIC ANALYSIS:




Load, F = 5000 N



Area =

5000

7520= 0.664 MPa


Fig: 4.15 Boundary Conditions


ANALYSIS OF EXISTING DESIGN:


4.8.2 DEFORMATION PLOT





4.9 MODAL ANALYSIS FOR EXISTING

DESIGN ALUMINIUM ALLOY 6061:

Deformation plots for different Natural

Frequencies:

Table: 4.4 Frequency Modes of Existing Design

with Aluminum Alloy

MODES FREQUIENCES (Hz)

MODE 1 0.2351

MODE 2 0.8109

MODE 3 0.8935

MODE 4 1.2800

MODE 5 2.0496

Table: 4.5: MATERIAL PROPERTIES OF

Von-Mises Stress and Maximum Deformation

Material Von-Mises

Stress

(MPa)

Maximum

Deformation

(mm)

AISI 1040 218.2 2.062

Aluminium

Alloy 6.334 215.9

4.11 DESIGN AND ANALYSIS OF NEW

DESIGN-1 WISHBONE ARM:

4.11.1 2-D DRAWING OF NEW DESIGN-1

WISHBONE ARM:





Fig: 4.27 2-d drawing of new design-1 wishbone

arm:

4.11.2 3-D Model of New Design-1 Wishbone Arm

4.12 Finite Element Model of Existing Wishbone

Arm:

Fig: 4.28 CAD Model of New Design-1

Fig: 4.29 Finite Element Model of New

Wishbone Arm

Design-1 Wishbone Arm

ANALYSIS WITH ALUMINIUM 6061

Table: 4.6 MATERIAL PROPERTIES OF AISI

1040:


POISSONS RATIO 0.33




STATIC ANALYSIS:




Load, F = 5000 N



Area =

5000

7520= 0.664 MPa



ANALYSIS OF NEW DESIGN:







4.13.3 MODAL ANALYSIS OF EXISTING

DESIGN FOR ALUMINIUM 6061:

4.13.4 Deformation plots for different Natural

Frequencies:

Fig: 4.40 Mode-4 plot Fig: 4.41

Mode-5 plot

Table: 4.7 Frequency Modes of New Design-1

Wishbone Arm

MODES FREQUEINCES

MODE 1 0.2285

MODE 2 0.9817

MODE 3 1.0175

MODE 4 1.5512

MODE 5 2.3332

Table: 4.8 Material values for von-mises stress

and max-deformation.

Material Von-Mises

Stress

(MPa)

Max-

Deformation(mm)

AISI 1040

(Existing

Design)

218 2.062

Aluminium

(Existing

220 6.3





Design)

Aluminium

(New Design-

1)

64 1.7

4.14 DESIGN AND ANALYSIS OF NEW

DESIGN-2 WISHBONE ARM:

Fig: 4.42 2-d drawing of existing wishbone arm:

4.14.1 3-D MODEL OF EXISTING WISHBONE

ARM: 4.14.2 FINITE ELEMENT MODEL OF

EXISTING WISHBONE ARM:

Fig: 4.43 CAD Model of Existing Wishbone arm

Fig: 4.44 Finite Element Model Existing Wishbone

Arm

4.15 ANALYSIS WITH ALUMINIUM 6061

Table: 4.9 MATERIAL PROPERTIES OF AISI

1040:


POISSONS RATIO 0.33




STATIC ANALYSIS:




Load, F = 5000 N



Area =

5000

7520= 0.664 MPa



ANALYSIS OF NEW DESIGN:



Fig: 4.46 Von-Mises Stress Plot Fig: 4.48

Deformation Plot

Maximum Stress = 74.56 MPa Maximum

Deformation = 2.167 mm

MODAL ANALYSIS OF EXISTING DESIGN

FOR ALUMINIUM 6061:

4.16.3 Deformation plots for different Natural

Frequencies:

Table 4.10: Frequency Modes of Existing

Design

Modes Frequeinces (Hz)

Mode 1 0.2184

Mode 2 0.9928

Mode 3 1.0294

Mode 4 1.5110

Mode 5 1.9577

Table 4.11: Material properties of von-mises

stresses and deformation.

Material Von-mises

stresses

(MPa)

Deformation

(mm)

AISI(ED) 218 2.062

AL(ED) 220 6.3

ND1 63.67 1.715

ND2 74.56 2.167





CONCLUSION

The main objective of this project is to

develop the model and perform the static and

model analysis of wishbone suspension arm.

From the above analysis it can be concluded that

1. The stresses and deformation is maximum

in the existing design with AISI 1040 of

218 MPa and 2.062 mm respectively.

2. The stresses and deformation for the

existing design with aluminium alloy is

almost maximum compare to AISI 1040.

3. In the existing design of wishbone

suspension arm is completely hallow and

it is welded joint, due to which there is a

chances of fracture at the welded joints.

4. New design has been developed to reduce

stresses and deformation existing in the

current design with aluminium alloy

which is completely moulded.

5. In the new design 1 and new design 2 of

aluminium alloy, the stresses are almost

reduced to 30% compare to existing

design.

6. The deformation in the new design 1 and

new design 2 is almost reduced to 10%

existing design.

7. Finally it can be concluded that from the FE

analysis the new design 1 and new design

2 can be replaced with aluminium alloy

existing design with AISI 1040 for

wishbone suspension arm.

REFERENCES/BIBILOGRAPHY

[1] Roslan Abd Rahman, Mohd Nasir Tamin, Ojo

Kurdi ―Stress analysis of heavy duty truck chassis

as a preliminary data for its fatigue life prediction

using FEM‖ Jurnal Mekanikal December 2008,

No. 26, 76 – 85.

[2] Cicek Karaoglu, N. Sefa Kuralay ―Stress

analysis of a truck chassis with riveted joints‖

Elsevier Science B.V Finite Elements in Analysis

and Design 38 (2002) 1115–1130.

[3] Mohd Azizi Muhammad Nora,, Helmi Rashida,

Wan Mohd Faizul Wan Mahyuddin ―Stress

Analysis of a Low Loader Chassis‖ Elsevier Ltd.

Sci Verse Science Direct Procedia Engineering 41 (

2012 ) 995 – 1001.

[4] N.K.Ingole, D.V. Bhope ―Stress analysis of

tractor trailer chassis for self-weight reduction‖

International Journal of Engineering Science and

Technology (IJEST), ISSN: 0975-5462 Vol. 3 No.

9 September 2011.

[5] Madan Mohan Reddy and Lakshmi Kanta

Reddy, “Modeling and Analysis of container

chassis using FEM”, International Organization of

Scientific Research Journal of Engineering

(IOSRJEN), Vol. 04, Issue 01 (January. 2014), pp.

34-37.

[6] Bhat KA, Untawale SP, Katore HV, “Failure

Analysis and optimization of Tractor Trolley

Chassis: An Approach Using Finite Element

Analysis”, International Journal of Pure and

Applied Research in Engineering and Technology

(IJPRET), 2014; Vol.2 (12), pp.71-84.

[7] Ketan Gajanan Nalawade, Ashish Sabu, Baskar

P, “Dynamic (Vibrational) and Static Structural

Analysis of Ladder Frame”, International Journal

of Engineering Trends and Technology (IJETT) –

Vol.11 Number 2 - May 2014, ISSN: 2231-5381,

pp.93-98.

[8] Abhishek Sharma, Pramod Kumar, Abdul

Jabbar and Mohammad Mamoon Khan, “Structural

Analysis of a Heavy Vehicle Chassis Made of

Different Alloys by Different Cross Sections”,

International Journal of Engineering Research &

Technology (IJERT), Vol. 3 Issue 6, June – 2014,

pp.1778-1785.

[9] Sandip Godse and D.A.Patel, “Static Load

Analysis Of Tata Ace Ex Chassis And Stress

Optimisation Using Reinforcement Technique”,

International Journal of Engineering Trends and

Technology (IJETT), Vol.4, Issue7- July 2013, pp.

3037-3039.

[10] Manpreet Singh Bajwa, Yatin Raturi and Amit

Joshi, “Static Load Analysis of TATA Super Ace

Chassis and Its Verification Using Solid

Mechanics”, International Journal of Mechanical

and Production Engineering (IJMPE), Vol. 1,

Issue- 2, Aug-2013, pp.55-58.

[11] Mohd Azizi Muhammad Nora, Helmi

Rashida, Wan Mohd Faizul ,Wan Mahyuddin,

Mohd Azuan Mohd Azuan,Jamaluddin Mahmud,

“Stress Analysis of a Low Loader Chassis”,

Elsevier Ltd. Sci Verse Science Direct Procedia

Engineering 41 ( 2012 ), pp. 995 – 1001.



issn: 2454-1362, design and ... · mr. jnanesh. k d a research scholar, mechanical engineering,...

Documents