International Journal of Science and Research (IJSR)

ISSN (Online): 2319-7064

Index Copernicus Value (2013): 6.14 | Impact Factor (2013): 4.438

Study of Fatigue Analysis of Vehicle Truck Chassis

doubt
objective or * Hailemariam Fisseha Nega1, Yang Hui2
important
1
Tianjin University of Technology and Education (TUTE) School of Mechanical Engineering, China
Names

Abstract: Now day’s Vehicle trucks plays a more important role in all economy activity of transportation. The major focus in the truck
manufacturing industries is design of truck chassis with more pay load capacity and possible less weight. And a number of analytical
and experimental techniques are available for the analysis of the automobile frames. An important aspect of chassis’ design and
analysis is the stress distribution and fatigue life of prediction process. The stress analysis is important in fatigue study and life
prediction of components to determine the critical point which has the highest stress. In order to achieve a reduction in the magnitude of
stress at critical point of the chassis frame, side member thickness, cross member thickness and position of cross member from rear end
were varied .Also, in order to avoid matching the natural frequency of the chassis with the excitation frequency, natural frequencies and
vibration modes have been analyzed during the loading conditions. Fatigue is one of the most important parameters to consider when
designing truck components. The components are typically subjected to dynamic loads when in service. In this paper, an effort is made
to review the investigations that have been made on the different fatigue analysis techniques of vehicle truck frames. A number of
analytical and experimental techniques are available for the analysis of the automobile frames

Keywords: Fatigue analysis, Vehicle truck, Chassis

1. Introduction involved in the chassis manufacturing technology and

development [2].The objective of this paper is to present the
The chassis of trucks is the backbone of vehicles and fatigue analysis techniques of vehicle truck frames.
integrates the main component systems such as the axles, Prevention of fatigue failure is one of the most important
suspension, power train, cab and trailer, and is usually parameters to when designing truck components. The
subjected to the weight of cabin, its content, and inertia components are typically subjected to dynamic loads when
forces arising due to roughness of road surfaces etc and in service. A number of analytical, numerical and
Transportation industry plays a major role in the economy of experimental techniques are considered for the fatigue
modern industrialized and developing countries. The early analysis of the vehicle truck frames. Conclusion of the
damages caused by heavy load reduce the road service life fatigue analysis in the vehicle chassis has been reported in
and ride comfort. Highway maintenance brings huge literature.
economic losses, while serious road failure threats traffic
safety. Chassis is one of the most significant components in 2. Aspect of Truck Chassis Frame
automotive industry and is considered as the bigger parts in
the vehicle. The chassis of trucks is tasked with holding all The common chassis frame consists of two channel shaped
the components systems together; hence it should be rigid side members that are sustained apart by many cross
enough to withstand the shock, twist, vibration and other members, as shown in Figure1. The cross members are
stresses. Along with strength, an important consideration in placed at points of high stress and are joined to side
chassis design is to have adequate bending stiffness for members. The depth of the channel must be enough to
better handling characteristics. So, maximum stress, reduce the deflection. Since the load at each point of the
maximum equilateral stress and deflection are important frame varies, a weight reduction can be achieved by either
criteria for the design of the chassis. The greater the energy minimums the depth of the channel, or having a series of
absorbed by the chassis on impact the lower the energy holes positioned along the axis in the regions where the load
levels transmitted to a vehicles occupants and surroundings, is not so high. On the normal road surfaces, the chassis
lowering the chances of injury [1]. The chassis of trucks frame is subjected to both bending and torsion distortion.
which is the backbone of vehicles that integrates the main The open-channel sections exhibit excellent resistance to
truck component systems such as the axles, suspension, bending, but have very little resistance to twist. From the
power train, cab and trailer etc., is one of the possible global torsion analysis, it has been found that the torsion
candidates for significant weight reduction [2].In general, load is more severe than bending load. In order to overcome
the chassis experiences several loading situations that this problem, a cross bar and material selection are very
include vertical bending, longitudinal torsion, lateral important to consider during design stage [4]. Therefore,
bending, torsion loading and fatigue loading [3]. In both side and cross-members of the chassis must be
additions, the chassis design includes the selection of designed to resist torsional distortion along their length.
suitable shapes and cross-section of chassis-members.
Moreover, the design should consider the reinforcement of
the chassis side- and cross member joints, and the various
methods of fastening them together. There are number of
parameters which affect the fatigue life of the structure as
listed: cyclic stress state, geometry, surface quality, material
type, residual stresses, size and distribution of internal
defects, direction of loading & grain size. Many researchers
in the automotive industry have taken this opportunity to be
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2013): 4.438

Figure 1: Construction of the common chassis frames

Generally for tracks commercial vehicle channel section is

preferred over hollow tube due to high torsional stiffness.
The chassis frame, however, is not designed for complete
rigidity, but for the combination of both strength and Figure 2: Fatigue crack of the sub-frame
flexibility to some degree. The chassis frame supports the
various components and the body, and keeps them in correct The stress analysis is important in fatigue study and life
positions. The frame must be light, but sufficiently strong to prediction of components to determine the highest stress
withstand the weight and rated load of the vehicle without point commonly known as critical point which initiates to
having appreciable distortion. It must also be rigid enough to probable failure, this critical point is one of the factors that
safeguard the components against the action of different may cause the fatigue failure. The magnitude of the stress
forces. The chassis design includes the selection of suitable can be used to predict the life span of the chassis. The
shapes and cross-section of chassis-members. Moreover, the location of critical stress point is thus important so that the
design should consider the reinforcement of the chassis side- mounting of the components like engine, suspension,
and cross member joints, and the various methods of transmission and more can be determined and optimized.
fastening them together [3]. Finite Element Method (FEM) is one of the methods to
locate the critical point. Safety factor is used to provide a
3. Fatigue Analysis of Truck Chassis design margin over the theoretical design capacity. This
allows consolidation of uncertainties in the design process
Fatigue is the phenomenon in which a repetitively loaded [3]. Chetan et al. [5] reviews various factors affecting the
structure fractures at a load level less than its ultimate static fatigue life of a structure like cyclic stress state, geometry,
strength, as shown in Figure 2. There are many parameters surface quality, material type, residual stresses, size and
that contribute to fatigue failures namely: number of load distribution of internal defects, direction of loading & grain
cycles experienced, range of stress experienced in each load size. Determining the stresses of a truck chassis before
cycle, mean stress experienced in each load cycle and manufacturing is important due to improvement in design.
presence of local stress concentrations [5]. Also, the fatigue An important aspect of chassis design and analysis is the
analysis refers to one of three methodologies: local strain or stress distribution and fatigue life of prediction process.
strain life, commonly referred to as the crack initiation Chassis analysis mainly consists of static analysis to predict
method, which is concerned only with crack initiation, stress stress distribution and subsequently, the fatigue simulation
life that commonly referred to as total life and crack growth to predict the life of the chassis. Many researchers carried
or damage tolerance analysis that is concerned with the out study on truck body components. Fermer et al. [6]
number of cycles until fracture. The main steps for investigated the fatigue life of Volvo S80 Bi-Fuel using
calculating fatigue life is sometimes called the Five Box MSC/Fatigue. Also, Fermer and Svensson in 2001 [7]
Trick, including material, loading, geometry inputs, analysis studied the mechanical finite element analyses of welded
and results. structures performed on a daily basis in the automotive
MSC=Mediterranean Shipping Company industry. One objective is to estimate the fatigue strength,
which is given mainly by the strength of the joints. This
article give some insight into the dimensioning process, with
Sprung mass is the load sitting on top of the special focus on fatigue analysis of spot welds and seam
springs and un sprung mass is the weight welds in thin-walled car body structures made of steel.
connected to the bottom of the suspension. Conle and Chu [8] did research about fatigue analysis and
the local stress –strain approach in complex vehicular
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Paper ID: SUB154400 1637
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2013): 4.438
structures. Moreover, Conle and Mousseau in 1991 [9] the fatigue cracking area. The influence of the weld
described an analytical study of the fatigue life of parameters on the structural stress concentration factors is
automobile chassis components using automotive proving also studied. Twelve specimens of every type were tested
ground load history results combined with recent and the test data are compared both to a nominal stress based
computational advances. This work advances knowledge in design SN curve Eurocode9/31 and a structural stress based
two ways: a vehicle dynamics model is used to generate the design SN curve Eurocode9/44. RoslanAbd Rahman et al.
history of the load vectors acting on the components and the [14] conducted stress analysis of heavy duty truck chassis by
element stress equivalency procedure used until now is utilizing a commercial finite element package ABAQUS. To
improved. It can be concluded that the combination of determine critical point so that by design modifications the
vehicle dynamics modeling, finite-element analysis and stresses can be reduces to improve the fatigue life of
fatigue analysis is a viable technique for the design of components. During this he uses ASTM low alloy steel a
automotive components. However, before our durability 710 C (Class 3) with 552 MPa of yield strength and 620
process can be suitable for applied engineering work a MPa of tensile strength for chassis founds the maximum
number of improvements are required, which has been stress 386.9 MPa at critical point occurred at opening of
outlined. Thompson et al. (1998) [10] discussed the design chassis This critical point is located at element 86104 and
and Analysis of a Winston Cup Stock Car Chassis for node 16045, which is in contacted with the bolt from this he
Torsional Stiffness using the Finite Element method. Roll concludes that this critical point is an initial to probable
stiffness between sprung and un sprung masses. The failure. Kurdi et al. in 2008, [15] discussed about the one of
application of the method is demonstrated using two case the most important steps in development of a new truck
studies, namely a road tanker and a load haul dumper. In chassis is the prediction of fatigue life span and durability
both cases, it was possible to obtain adequately accurate loading of the chassis frame. The age of many truck chassis
fatigue life prediction results, using simplified loading, static in Malaysia are of more than 20 years and there is always a
finite element analyses and a stress-life approach to fatigue question arising whether the chassis is still safe to use. Thus,
damage calculations, with material properties available in fatigue study and life prediction on the chassis is necessary
design codes. Fatigue life analysis and improvements of the in order to verify the safety of this chassis during its
auto body in a sports utility vehicle (SUV) were performed operation. Stress analysis using Finite Element Method
by Zhong and Ping in 2006 [11]. The stress distribution (FEM) can be used to locate the critical point which has the
under unit displacement excitation was obtained by the finite highest stress. Critical point is one of the factors that may
element (FE) method. A bilateral track model was adopted cause the fatigue failure. The magnitude of the stress can
to obtain load spectra in accordance with the vehicle used to predict the life span of the truck chassis. The stress
reliability test. The total life of the auto body was evaluated analysis is accomplished using the commercial finite
by the nominal stress method with the assumption of a uni element packaged ABAQUS by Velo so etal. [16]. They
axial stress state, and thus the critical regions were discussed the failure investigation and stress analysis of a
determined. The life of components with critical regions was longitudinal stringer of an automobile chassis Fiat Auto
further investigated on the basis of multi axial fatigue motives, Rod. Fernão Dias, km 429, Betim, MG, Brazil
theory. The results show that some components near to the Pontifical Catholic University of Minas Gerais (PUCMinas),
suspension are easy to damage because they are directly Mechanical Engineering, Belo Horizonte, MG, Brazil A
subjected to impact loading from the road. It is also prototype vehicle was submitted to durability test, on road at
indicated that the result from multi axial fatigue analysis is a proving ground test track. Failures of posterior
more reasonable than that from the nominal stress method, longitudinal stringers were observed during this test. Cracks
which was verified by experimental results. Finally, were nucleated on these stringers during durability test,
topological optimization of the spot weld location in the before the designed life of these components is reached.
critical region was carried out by the homogenization These cracks were observed at nearly the bumpers fixation
method to improve its fatigue life. In addition, Hoffmeyer et points of the vehicle suspension. Loads are transmitted by
al. in 2006 [12] discussed some issues in multi axial fatigue wheels to the body of the vehicle through the suspension
and life estimation is presented. While not intended to be components. Thus, the longitudinal stringers are subjected to
comprehensive, these are a relatively broad range of issues these localized cyclic stresses. Also, Palma et al. in 2009
which are commonly encountered when dealing with multi [17] investigated to analyze the fatigue behavior of an
axial fatigue. They include damage mechanisms, non- automobile body part, according to the standards of
proportional hardening and constitutive behavior, damage performance. The methodology is based on experiments
parameters and life estimation, variable amplitude loading, performed on a rear trailer tow hook pin of a passenger
cycle counting, damage accumulation, and mixed-mode automobile vehicle. Experiments were performed simulating
crack growth. Some simple approximations in capturing the actual conditions in the customer environment. Stress
some of these effects in multi axial life estimations are also and strain were experimentally measured by using strain
presented. In 2007, Ye and Moan [13] discussed static and gages, bonded on assembly critical points. Besides, stress
fatigue behavior of three types of aluminum box- analysis was also performed using a finite element program.
stiffener/web connections are investigated in this study. The Fatigue analysis is used to access and to compare the fatigue
main purposes are to provide a connection solution that can damage imposed during laboratory experiments. Recently in
reduce the fabrication costs by changing the cutting shapes 2011, Chen and Zhu [18] studied the YJ3128-type dump
on the web frame and correspondingly the weld process and trucks sub-frames, for the fatigue crack occurred in the Sub-
meanwhile sufficient fatigue strength can be achieved. Finite frame which has worked in bad condition for 3 to 5 months.
element analyses (FEA) show the influence of local The sub-frame was analyzed by ANSYS and the reason for
geometry and weld parameters on the stress gradient near the cracking of the frame was found according to the
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2013): 4.438
different stress. At last an improvement and optimization to Research Centre CESTI and directions of future
the structures of the frame was provided. Also Hengji et al. activities. International Journal of Fatigue. 2012;. 39:95-
in 2012 [19] explained the fatigue life for frame of the 220t 102.
mining dump truck, a fatigue life analysis method was [4] G. Murail, B. Subramanyam and D. vaveen “Design
presented by integrating multi body dynamic analysis and Improvement of a Truck Chassis based on Thickness”
finite element method. The forces of main joints at frame Altair Technology conference , India, 2013.
were measured from the multi body dynamic model, whose [5] J. Chetan S., Panchal Khushbu C., Patel Fajalhusen “A
road was restructured. The dynamic stress test of the whole Review of the Fatigue Analysis of an Automobile
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ensured. The quasi-static stress analysis method was Analysis of Volvo S80 Bi-Fuel using MSC/Fatigue,
employed to acquire stress influence coefficient under unit Worldwide MSC Automotive Conference, and
load, which was associated with load histories of the frame Germany, 1999.
to get the dangerous stress area. The fatigue life of the frame [7] M., Fermér and Svensson, H. Industrial Experiences of
was calculated on the basis of Palmgren–Miner damage FE-based Fatigue Life Predictions of Welded
theory. It was turned out that the minimum life area of the [8] Automotive Structures,Fatigue &Fracture of
frame is located at the frame joints of suspension, which Engineering Materials and Structures 24 (7), 2001, 489-
matches the practice. More recently, Bhat et al. in 2014 [20], 500.
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existing trolley chassis designed by industry uses „C‟ Cross Local Stress-strain Approach in Complex Vehicular
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material used was mild steel. By keeping the material and DOI:10.1016/S0142-1123(97)00045-5.
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in weight. They concluded that the Reduction in weight fatigue life contours for chassis components.
shows that raw material required for manufacturing of the International Journal of Fatigue.13, 3(1991), pp. 195-
Chassis was reduced. Also, they obtained safer stresses in 205. [10] L. Thompson. Srikanth Raju and E. Harry
new suggested design and increase in factor of safety Law “Design of a Winston Cup Chassis for Torsional
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[11] DU Zhong-zhe, ZHU Ping,HE Jun, Fatigue lifetime
4. Conclusion analysis of auto-body structure and spot weld based on
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number of previous works. some of the previously [12] J. Hoffmeyer, Doring, R.; Seeger, T.; Vormwald, M.:
conducted work related to vehicle structural design, analysis Deformation behaviour, short crack growth and fatigue
and optimization is surveyed. It is found that the chassis lives ¨undermultiaxial non proportional loading. Int. J.
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weak points and fatigue analysis to predict the life of the [13] N. Ye, and T. Moan, Static and Fatigue Analysis of
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