Design and Analysis of Tipper Truck Chassis

by
Sandeep Meena
(2011132)

Supervisor
A K SINGH

Mechanical Engineering Discipline

INDIAN INSTITUTE OF INFORMATION
TECHNOLOGY, DESIGN AND MANUFACTURING
JABALPUR
(15 Days Work Report)
(1thJune to 15th June, 2016)

1. Introduction
The truck industry is a significant lifeline of the countrys economic activity. There is
considerable scope to improve the design of their products. trucksare used mainly for
commercial purpose that is used in primary sector industry where it is used for loading sand, soil,
iron ore and for transporting them from one place to another etc. trucks is equipped with several
body part such as open-box bed, which is hinged at the rear and equipped with hydraulic
pistons to lift the front, allowing the material in the bed to be deposited ("dumped") on the
ground behind the truck at the site of delivery. The bed is raised by a vertical hydraulic
ram mounted under the front of the body, or a horizontal hydraulic ram and lever arrangement
between the frame rails and the back of the bed is hinged at the back of the truck. So the design
of chassis of the truck is of significant importance.
The base of any truck is its chassis. Chassis is the main frame of any truck body that supports the
whole truck. It also carries the load and the several body part of truck, so the intensity and
strength of truck body is the most concerned part to be analyzed. The static intensity of the frame
has been analyzed when exposed to pure bending and torsion stress, within two cases. First case
is when the rear wheels zigzag gets over block (only one side of the chassis steps the block), and
the second case is when both wheels gets over the block (loaded). So, the intensity and the
strength of the frame play a big role in the truck's design.
Suspension and chassis technology is defined as the sum of all vehicle systems that are
responsible not only for the generation of forces between the tires and the road surface, but also
for the transfer of these forces to the road in order to enable driving, steering, and braking. The
frame of the standard dump truck supports all types of complicated loads coming from the road
and freightbeing loaded. So, the intensity and the strength of the frame play a big role in the
truck's design. A vehicle with an optimally tuned chassis is easier to drive, since the drivers
inputs are quickly, predictably, and precisely followed.A better, safer chassis greatly increases
the chances of a vehicle staying on the roadway.

2. Objectives

The main objectives of the research are as follow

To develop optimized improved design for existing truck chassis.

To improve the static and dynamic behavior of the truck chassis by changing the
geometrical dimension and structural properties.

To determine the torsion stiffness and static and dynamic mode shape of the truck chassis
by using torsion testing, modal analysis and finite element method (ANSYS)

To reduce the weight of the body (overall optimized model)

Determination of critical point for highest stress (equivalent stress)

Modification of design for existing design of chassis in regard of body weight, maximum
deformation, torsion, and performance.

3. Methodology
The methodology of work is outlined below:

Geometric Modeling of three models of commercial trucks cassis assembly in Catia,

ZWCAD, Adams, Solidworks.

Static analysis for three models of chassis of the truck for same (geometric, volumes)
geometric features and loadingconditions. In order to solve the problem of the project, a
detailed finite element analysis is proposed to determinethe total deformation and
Equivalent stress in static condition using the analysis software ANSYS WORKBENCH.

After analyzing the three models of chassis, a Fourth model (optimized) is developed and
analyzed.

4. Report on the present investigation/progress during

the period of 15 days
During the design of truck chassis, a number of factors have to be considered. The most
important factors are as follow:
(a) Selection of type of the chassis.

(b) Selection criteria -The induced stress and material properties.

The second most important factor for the determination of the chassis is the powertrain
configuration.This layout determines the position of the engine and the driving axles.
The three main layouts are:
Front-engine
Mid-engine
Rear-engine
With the following variants for motor orientation:
Longitudinally-mounted
Transverse-mounted
Three possibilities for the position of the driving axles:
Front-wheel-drive
Rear-wheel-drive
All-wheel-drive

5. Type of Tipper Truck chassis

Fig.1 (4x2, 06 wheel Tipper Truck Chassis)

Fig.2 (8x2, 10 wheel Tipper Truck Chassis)

Fig.3 (8x4, 12 wheel Tipper Truck Chassis)

6. Selection of material for Chassis

The following factors are considered while selecting material for the design of truck chassis:
(a) Suitability of the material for the working condition
(b) Availability of the material
(c) Cost of the material

7. Result and discussions

We have studied various types of truck and their design. We studied about their functionality
and focused on our prime research area that is design of chassis. We studied thoroughly about
the mechanism and design of chassis for different configurations of chassis like front wheel
drive, rear wheel drive, and all-wheeldrive for different model of trucks. We mainly studied the
model of Tata motor, Ashok Leyland, Mahindra & Mahindra and Volvo.

8. Conclusions
We have studied the documentation of the entire different truck model from above depicted truck
company. We find that still there is need to improve the design of chassis with best optimized
result in term of reduced body weight, torsion, deformation and minimum stress. We will be
using Catia software for designing the model for study and Ansys workbench for analyzing the
various parameters and ZWCAD for dimensioning.