Client Tamilnadu State Express Transport corporation Reference No. CTC/0101210801 Design Algorithm Input/Computations/Decisions 100 Description, location and overall geometry of product a. Purpose of the vehicle Bus/Truck(t)/Cargo truck/ Refrigerated truck ( R ) others B b. Kind of body Struture Stiffned panel/Sandwich/grid Stiffened/grid c. Shape of body configuration Retagular ono box shape/two box Rectangular one box shape d. Shape of front and rear Flat/Curved streamlined Flat 102 Dimensions a. Overall length L in mm 10,100 b. Overall Width B in mm 2430 c. Height of side walls H above the chassis in mm 2350 102 Internal arrangements a. Whether separate driver's cabin provided yes/No No b. The lenth ld of drivers cabin in mm NA c. Whether the passenger/ Cargo cabin is integral with drivers cabin or separtely on a trailer NA d. Location, Width Wd and height hd of driver entry door in mm 700 e. Location, Width Wd and height hd of helper entry door opposite drivers door in mm 700 f. If driver cabin is separate, length Lc of cargo cabin in mm NA Design Input Design of all composite busbody g. Whether the top is covered or open 30 h. If top is open height hf of the side walls NA i.. If top is open whether the side walls can be rigity fixed or hinged for loading and un loading NA j. Whether the bus is ordinary (OB),Luxury bus(LB), or Air-conditioned bus(AB) k. No of passengers seats to be fixed 45+2 l. No. Of additional passengers allowed to travel as standees 60 m. Cargo weight Wc to be permitted inside in kg 1000kg n. No . Of seats per row 4 o. Distance between successive row,ls of seats in mm 1000 p. Self weight of seats in kg 20kg q. Method of fixing of seats Fixed on the floor board by bolting Fixed on floor board r Whether luggage carrier racks/ boxes to be provided yes s. Whether interior padding is to be provided on the side walls Yes if 1025 is LB or AB NA t. Location width We and height he of passanger entry door in mm 700 u. Location width Wpc and height hpc of passanger entry door in mm This can be same as helper entry door in 1012 if the driver cabin is integral with passanger cabin 700 v. If the bus is AB, Temperature T in C inside during operation NA x. w. If the bus is AB, location and weight of air conditioner in kg NA x. Type of cargo Vegetables/Meat/ Fish /Others NA y. Whether the cargo can exert weight on walls during acceleration / deceleration / storage / or while negotiating curves No. of the cargo is firmly fixed on floor with gap between wall and cargo NA z. Location width Wr and heighy hr of the cargo door NA bb Whether metallic lining is required inside to take local impacts NA cc. Temperature oc cabin in C NA dd. Whether insulated container only with no AC or with refrigerator attached NA ee. if with refrigerator location and weight of refrigerator NA 130. Support conditions a.Whether to be supported in chassis (SC) or to be an integral monocoqe shell(SM) SC b.If 1061 is SC No . And dimensions of longitudinal beams in chassis over body to be supported Two channels 229mm x 76mm x 6.35mm c.Spacing Wc of chassis beam in mm 840 d. Environmental temperature in C 45 e. Design temperature Dt in C ( if not given takes as 90 C for vehicles exposed to sunlight on outside pannel 90 f. Minimum environmental temperature in C 15 C g. Minimum design temperature DTM in C DTM can be minimum of 1073,1054,1037 15 C 110. Major product elements of busbody and dimensions 120. Functional requirements m. Expected life given in running km 3x 10^5 KM 130. Operational Static and Dynamc loads a. Total design pay load in kg Wp Wp is passanger and cargo / luggage weight 9000kg b. Snow load Ps on roof in N/mm2 if not applicable take Ps as zero NA c. Self weight of body in kg Assumed 50% of pay load for deign purpose 5000kg d. No. of fitting with concentrated load effect their location and weigh tin kg give sl. No. location as distance in mm from front and weight in kg under 3 column on right hand side 6150N 131. Aerodynamic loads a. Pressure acting on front end on roof and front wall rear walls pa in N/mm2 rear end b. wind pressure Pw in N/mm2, when vehicle, is stationery in N/mm2 Not to be considered c. Impact factor a a. Vertical accelerator mZS for symmenric load b. Vertical accelerator mZU for unsymmenric load c. Longitudinal l accelerator or load factor mSC d. Load factor for corning mY e.Load factor for kerbing mK f. Load factor for turn over mR 2.5 1.3 0.7 1.0 1.0 1.5 d. Fatigue design load and the no. of cycles during lie period 10^6 e. Normal operational speed Vm in km ph 60 f. Peak operational speed Vp in km ph 100 g. Frequency vibration due to traffic or other wise in HZ 50 h. Corrosion or chemical attack nil i. whether moisture effect can give degradation Nil effect j. whether moisture effect can give degradation Impact in sea coast and places where deicing is done Negligible k. whether thrmal stresses can arise due to thermal expansion or thermal gradient NO l. Whether degradation due to fire, friction UV radation other radiations, biological attacks or lightning to be considered NO 200. Selection of geometry in addition to wht is alredy taken in input data 210. Manufacturing method 2. Design selections a. If to be designed as per any standard, specify standard no No b. Type body construction Steel frame and panel (SP) / steel and sandwich (SS)/Steel and grid (SG)/ all sandwich with no steel (AS) / all grid with no steel (AG) SP for wall,Sg for floor and SS for roof c. If 2002 is not FP go to d. Spacing of cross steel arches lse in mm ( Normally these can be considering with the seat spacing so that a windows can be provided in between frame for passangers sitting in each row to see outside) 1000mm e. No of frame nf in long direction nf = (L or Lc)/ Ise +1 10100/1000+ 1=11 f. No.of lingitudinal members of steel frame excluding bottom panel 9 g. Location of lingitudinal beam If must be such that windows can be placed without obstruction 9 h. Spacing of cross members on the floor panel lsf in mm Keep it same as that of the wall cross members 1000 i. No.of lingitudinal members on the floor panel and that spacing wsf in mm 13 j. Method of joining of steel members Welding / Bolting Welding k. Type of panel between steel frame on the floor Sandwich / Grid / stiffened panel / single skin grid l. Tytpe of panel on roof Sandwich / Grid / stiffened panel / single skin Sandwich m. Type of panel on side wall Sandwich / Grid / stiffened / single skin Single skin n. Type of panel / or the front end for impact resistence stiffened o. Panel structure of single skin Flat / corrugated Flat p. Panel material E-glass CSM-Polyester q. Grid material E-glass UDC-Polyester r. Sandwich material E-glass CSM-Polyester and polyurethane s. Grade polyester resin Isophthalic is to be used automobile grade for ompact resistence Isophthalic t. Heat distortion temperature HDT of resin in C HDT < 100 100 u. Gel coat resin and thickness Normally 0.5 mm thickness 0.5 v. Whether gel coat to be pigmented Yes if not painting is planned no w. UV stabiliser material its grade and percentage Tinovin 0.1% x. Pigment grade colour and percentage NA y. Whether filler can be added to lay up at if so name of material and percentage Yes 10% maximum Calcium carbonate z. Area density Wcsm of CSM in gsm 450 aa. Text of rovings for grid constrution 2400 ab. Area of density of WRM to be used 610 Selection of design criteria a. Whether to be designed by strength of material approach only/strength of materials for preliminary selection and FEM for optimisation strength of materials for each element as Fem for final assembly design b. Whether design for functional requirements to be under taken Not provided in this modle No c. Any design for safety under non- mechanical /environment effects to be considered No d. factor of safetyv 6 DESIGN FOR SAFETY a. Weight of passanger Wp in N Wp = n p 90 x 9.81 9000 x 9.81 =88290 b. Chassis weight Wc in N 37200 Weight of front axle with wheel and axle in N 10,000 Rear axle with wheel and acceleration in N 14,050 Weight of milds / is stracture in its body and floor in N 13000 Weight of the ghaged windows in N 4500 Weight of the 50 suels in N 7500 Weight of mi fillling in N 6150 Design of roof Phril a. Type of stracture Sandwich with form wire b. Span ls in mm 1000 c. Width of panel Ws in mm 2430 d. Assumed stractural behaviour Plate if Ws < 2l s beam if Ws > 2ls beam Design palm load on moffing in N 25 x 90 x 9.81 = 22072.5 Design pressure Pd in N/ mm2 22072.5/10100 x 2430 =0.0008993 Assumed skin thickness no of sand with t in mm Assumed 2 mm min / mm 2 in CSM 450 mat Assumed core thickness C in mm 25 Moment of inertia I = 2 t/2 + 2 (25F x t / 2 )2 t 2 x 2^3 / 12 + 2 (25+1)2 x 2 Deflection ymax in mm y max = 1/38h x Pl x l s ^4 / EI 1 x 0.0008993 x 1000^4 / 384 x 6300 x 2705 = 0.1374 if deflection is acceptable yes if y max < span / 200 Yes Bending moment M in N-mm / mm M = Pd . L s^2 / 8 0.0008993 x 1000^2 / 8 = 112.4125 Allowable bending moment Mal 12.5 x 2 x 27 = 675 If design acceptable Yes if M < Mal yes Design of bottom panel Type of stracture Grid floor span lb in mm 1000 Width wb in mm 2430 Assumed stractural bed view Equalent or plate Spacing a of grid beam placed in the axial direction in mm 100 thickness tl of grid beam placed longitudnally 10 Spacing b of grid beam placed longitudnally in mm 100 Thickness tt of grid beamplaced 10 Depth of beam dh in load in loaded direction in mm 50 Depth dt of beam in direction 25 Dx = El t l dl ^3 / 12 a 30000 x 10 x 25 ^3 / 12 x 100 = 3906250 x 8 Dy = El t l dl ^3 / 12 a 3906250 x 8 2H = 2a (Jl / a + Jt /b 7812500 x 8 Distributed load (88290+ 7500 + 6150) / 10100 x 2430 = 0.0041535 Deflection Ymax in mm y max = 16 p d / 3.14^2 D 16 x 0.0041535 x 10^6 / 3.14^2 x 5.34133 x 8 = 15.075 mm Bending moment Mx in N-mm ml = 16 p d a / 3.14 ^4 x w^4 [D] 16 x 0.00415.35 x 100 / 3.14^4 x 1000^4 x 8 x 5.3413 x 10^-6 = 1.5998 x 10 ^-9 Bending moment Mx in N-mm ml = 16 p d a / 3.14 ^4 x w^4 [D] 16 x 0.00415.35 x 100 / 3.14^4 x 24830^4 x 8 x 5.3413 x 10^-6 = 4.5883 x 10 ^-11 ``` 0.004115226 5467.5 0.127503188