Analysis of Transverse Link under Static and Dynamic Loading Conditions

Transcription

1 Analysis of Transverse Link under Static and Dynamic Loading Conditions Rahul D. Sherke *1, A.P Tadamalle *2 * PG Scholar, ME Automotive Engineering, Sinhgad College of Engineering, Vadgaon (BK), Pune, Maharashtra, India ** Associate Professor, Mechanical Engineering, Sinhgad College of Engineering, Vadgaon (BK), Pune, Maharashtra, India ABSTRACT A transverse link is an important component of the suspension system is keeps motor vehicle in controlled swerving when running on uncertain road condition. The transverse link is the better shock absorber than the upper arm, since it has better loading capacity. This study aims to design and development of transverse link of Macpherson suspension system and its static analysis under static and dynamic loading condition. The reverse engineering of existing transverse link of Indica-V2 is done by using blue light scanning and same has been planned to model using Catia-V5 software and meshing of model is done by using Hyper-mesh The linear static analysis of transverse link is planned to perform under static and dynamic loading condition to predict stress and deformations. Topology optimization can be done in minimum stress region of transverse link. Finite element analysis is doing by Ansys The result obtained from analysis is compared with existing model. The Macpherson suspension system is used in light motor vehicle and the outcome of this research work provides better riding comfort during driving over uncertain road condition and with variable speed. Keywords: Suspension System, Transverse Link, Reverse Engineering, Topology, FEA Analysis. 1. INTRODUCTION The general function of control arms is to keep the wheels of a motor vehicle from uncontrollably swerving when the road conditions are not smooth. The control arm suspension normally consists of upper and lower arms. The upper and transverse links have different structures based on the model and purpose of the vehicle. By many accounts, the transverse link is the better shock absorber than the upper arm because of its position and load bearing capacities. In this study Macpherson strut suspension system with Transverse link is considered. It has an A shape on the bottom known as wishbone shape which carries most of the load from the shock received. The transverse link takes most of the impact that the road has on the wheels of the motor vehicle. It either stores that impact or sends it to the coils of the suspension depending on its shape. The present study will contribute in this problem by using finite element analysis approach. Topology optimization is a powerful optimization technique designed to provide engineers with a tool of evaluating and expanding the solution space and increasing creativity when designing and dimension load carrying structures, both on a micro and macro scale. By assigning a valid design space and the proper Boundary Conditions; loads, design responses and constraints, commercially available software are able to predict the optimal structure for the application. The work order and general sequence of work is valid for most commercial software. By default, all types of discrete topology optimization algorithms have the disadvantage that the product of the optimization is a non-smooth structural geometry. As many engineering applications require smooth geometric shapes, a smoothing procedure has to be performed.the control arm is an important component of suspension system. As vehicle passes through bump, speed breaker then different types of forces acting on the wheels which are transmitted to control arm through attachments of the ball joint assembly and to the wheel. These force and torque values are mention in the load case. So in this analysis the main concern is to find out the maximum stress region and stress value in control arm and compare this value with existing model. 2. LITERATURE REVIEW Jong-Kyu Kim, Seung Kyu Kim, et al [1], in this research, the shape of upper control arm was determined by applying the optimization technology. This study considers the static strength in the optimization process. In this study, the kriging interpolation method is adopted to obtain the minimum weight satisfying the static strength constraint. The real experiments on 1/4 car is conducted to validate the FEM analysis. At last, the correlation of each case about durability life is obtained. Lihui Zhao, Songlin Zheng, et al [2] Dynamic Structure Optimization Design of Lower Control Arm Based on ESL describes the new design obtained from the results of dynamic optimization based on ESL method can satisfy the actual requirements of manufacturing process. Structure dynamic optimization based on ESL method can avoid the dependency on personal experience, improve the accuracy of the optimal results, meanwhile decrease the time in product design. Vinayak Kulkarni, Anil Jadhav, P. Basker [3] Finite Element Analysis and Topology Optimization of Lower Arm of Double ISSN: Page 413

2 Wishbone Suspension using RADIOSS and Optistruct in this research paper on strength basis, aluminium alloy is good material than Mild Steel whereas on strain basis, Mild Steel is good material than aluminium alloy. Modes and mode shapes of lower control arm contingent on material properties. Hence change in material leads to change in resonance condition. Modes are used as a simple and efficient means of characterizing resonant vibration. Sagar Kailas Darge, et al [4] Review on Design and Evaluation of Suspension Arm for an Automobile Using FEM in this research paper From the review of the literature on structural analysis lower suspension arm it is seen that there is a scope for research work in the area of stress analysis of the lower suspension arm. As such, it is proposed to carry out theoretical and experimental studies on stress analysis of lower suspension arm used in light commercial vehicles. Jagwinder Singh, Siddhartha Saha [5] Static Structural Analysis of Suspension Arm Using Finite Element Method describes the Stresses of material fall within yield stress, hence design is safe. Deformation is more at ball bearing of suspension arm. P.Nagarjuna, k. Devaki Devi [6] Design and Optimization of Sheet Metal Control Arm for Independent Suspension System The weight of the component is decreased by 25% i.e. the weight of the forged model is 4.32 kg and the weight of the sheet metal model is 3.23kg. Sheet metal component is easy to manufacture, ball joints of different standards can be used and sheet metal control arm is more beneficial than forged control arm. 3. OBJECTIVES The main objective of this study is to find the stresses and displacement under various loading conditions. Modeling of transverse link by using Catia- V5 with the help of reverse engineering and meshing. Static analysis of the transverse link is to find out von-misses stresses in ANSYS. Static analysis deformation plot in ANSYS. In geometry preparation, a 3D scanning technology has been adopted to get the exact dimensions of the model. The 3D model in many cases should not only look visually similar to the real object, but it gives also a very accurate, from a geometrical point of view. Input parameters will be getting through reverse engineering process. The reverse engineering process is done with the help of blue light scanning. 3D-Model is done in Catia V5. Mesh the model in Hyper-mesh by using 10-noded tetrahedral elements. When a car is moving, determine the road bump case and braking case, Apply the required boundary conditions on existing model of transverse link and carryout static analysis. Topology optimization can be done. Again CAD, Meshing, Re-analyzed of optimized model. Fabrication & Testing will be carried to validate analysis results. 5. MESH GENERATION In this stage IGS file is imported to the Hyper-mesh meshing software. The CAD model data of the transverse link is imported and the surfaces were created and meshed. Since it s a 3D model, the best element for meshing is tetra element. A structure or component consists of infinite number of particles or points hence they must be divided in to some finite number of parts. In meshing divide these components into finite numbers. Dividing helps to carry out calculations on the meshed part then divide the component by nodes and elements then to mesh the components using 3D element. Tetrahedral 10-node elements were used to mesh the transverse link. 4. METHODOLOGY The cad model of transverse link is shown in Fig.1. Fig.2 Meshed Model of Transverse Link Number of nodes and elements formed after meshing are and respectively is shown in Fig.2. While meshing mesh size of an element is to be taken into consideration because all software s have some limits for the number of elements. After meshing elements are to be checked for Quality i.e. elements have some definite quality criteria which should be met by all elements. Fig.1 Cad Model of Transverse Link ISSN: Page 414

3 6. BOUNDARY CONDITIONS Tata Indica-v2 transverse link is considered. The loadings for two different cases of road bump and braking are calculated. For all calculations the mass of the vehicle was split according to the distribution at each corner. The weight distribution ratio in front side and back side =54:46 (As engine is in front side). The Gross vehicle weight (GVW) =1080 kg. Therefore, Weight on rear side =496.8 kg. Weight on one side of wheel =496.8/2 = kg. For the given input, various loads and forces acting on Transverse link are calculated. Various forces are shown in Fig.3. Vertical force= 1000 N Braking force= 1250 N Table.1 Material Properties: Property Value Young s Modulus, E 210 GPa Poisson s Ratio,ν 0.29 Density, ρ 7850 kg/m 3 Yield stress, y 6.1 Road Bump Case: Let, Speed of vehicle = 14 Km/hr. 290 Mpa Fig.3 Constraints and Forces Applied on Transverse Link 7. RESULT AND DISCUSSIONS We can analyse the Stress and Displacement of existing transverse link and optimized transverse link. 7.1 Existing Model Analysis I. Stress Analysis: In existing model of analysis of transverse link is subjected to high stress region as shown in fig.4. The maximum von misses stress is found to be Mpa. Red color indicates maximum stress region whereas blue color indicates minimum stress region. 6.2 Braking Case: Vehicle is decelerates (i.e.braking) at a constant value 0.5G. Fig.4 Existing model Von-misses Stress II. Deformation Analysis: In existing model of analysis of transverse link, the total deformation observed in transverse link is 0.65 mm is shown in fig.5. It shows the deflection of transverse link with respect to its constraints and will deflects from its original position. ISSN: Page 415

4 Fig.5 Existing Model Total Deformation 7.2 Topology Optimization Topology optimization is aimed to find the best use of material within a given design full-fill the requirements on stiffness, displacement, eigenvalues, etc. In short, the optimization seeks to the optimal load path for a particular load and boundary condition. With the rise of the Finite Element Method (FEM), algorithm-based optimization has become available not only to the expert user. Topology may be used to improve not only structural performance, but also thermal properties, fluid flow, electric boards (MEMS), electromagnetic applications and biomechanic properties. The material optimized region is shown in Fig.6 which has minimum stress region. Fig.7 Optimized Model Von-misses Stress II. Deformation Analysis: In optimized model of analysis of transverse link, the total deformation observed is 0.66 mm is shown in fig.8. It shows the deflection from its original position. Fig.8 Optimized Model Total Deformation Table.2 Results: Parameters Stress Deformation Existing Model Mpa 0.65 mm Fig.6 Optimized Transverse Link 7.3 Optimized Model Analysis In this stage existing transverse link is optimized by topology optimization process. Optimized Model Mpa 0.66 mm I. Stress Analysis: Optimized result gives reduction in stresses. Vonmisses stress value of transverse link is observed to be N/mm 2 which is well below the critical value as shown in Fig.7. Hence, design is safe. 8. EXPERIMENTAL VALIDATION The experimental investigation is performed on fabricated prototype on universal testing machine. Compression test has been performed on the transverse link. The input conditions are recreated in the lab while the component is being tested. The loading and the boundary conditions are matching the ISSN: Page 416

5 International Journal of Engineering Trends and Technology (IJETT) Volume 37 Number 7 - July 2016 practical working conditions in which the Product is expected to perform. It is observed that the maximum deformation occurred is 0.72 mm is shown in Fig Load (N) Deformation (mm) Fig.9 Load vs Deformation Mathematical calculation of percentage error after testing is given by, Percentage Error = Experimental FEA / Experimental 9. CONCLUSIONS The stress level in modified transverse link is reduced by 22.1Mpa. In modified model, total deformation in the transverse link is 0.66 mm. In experimental model, total deformation in the transverse link is 0.72 mm. In validation, the percentage error between FEA and Experimental model is 8.33%. ACKNOWLEDGMENT I would like to thank you my respected Guide Prof. A.P Tadamalle for providing guidance, support & valuable time to me for preparation of this paper work. REFERENCES [1] Jong-Kyu Kim, Seung Kyu Kim, Hwan-Jung Son, Kwon Hee Lee, Young Chul Park, Structural design method of a control arm with consideration of strength, proceedings of the 9th wseas int. conference on applied computer and applied computational science ISSN: , ISBN: [2] Lihui Zhao, Songlin Zheng, Jinzhi Feng And Qingquan Hong, Dynamic structure optimization design of lower control arm based on ESL, research journal of applied sciences, engineering and technology 4(22): , 2012 ISSN: [3] Vinayak Kulkarni, Anil Jadhav, P. Basker, Finite element analysis and topology optimization of lower arm of double wishbone suspension using Radios and Optistruct, international journal of science and research ISSN (online), impact factor (2012): 3.358, Volume 3 Issue 5, May 2014, PP [4] Sagar Darge, S.C. Shilwant, S. R. Patil, Finite element analysis and topography optimization of lower arm of double wishbone suspension using abacus and Optistruct, journal of engineering research and applications ISSN: , vol. 4, issue 7, July 2014, pp [5] Jagwinder Singh, Siddhartha Saha, Static structural analysis of suspension arm using finite element method, international journal of research in engineering and technology e ISSN: ISSN: , Volume: 04 Issue: 07 July-2015, PP [6] P. Nagarjuna, K. Devaki Devi, Design and optimization of sheet metal control arm for independent suspension system, international journal of engineering research and applications (IJERA) ISSN: vol. 2, issue5, September- October 2012, pp [7] Dr. Y. R. Kharde, Analysis of lower control arm in front suspension system using F.E.A approach, international journal of engineering research and development e-issn: x, p-issn: x, volume 5, issue 12 (February 2013), pp [8] Xue Guan Song, Ji Hoon Jung, Hwan Jung Son, Joon Hong Park, Kwon Hee Lee, Metamodel-based optimization of a control arm considering strength and durability performance, Elsevier, computers and mathematics with applications 60 (2010), PP. 976_980. ISSN: Page 417