DESIGN ANALYSIS OF EXTERIOR CAR BODY PART BASTIAN WIBAR BIN MOMANG

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1 DESIGN ANALYSIS OF EXTERIOR CAR BODY PART BASTIAN WIBAR BIN MOMANG Thesis submitted in partial fulfillment of the requirements for award of Bachelor of Mechanical Engineering with Automotive Engineering Faculty of Mechanical Engineering UNIVERSITY MALAYSIA PAHANG JUNE 2013

2 UNIVERSITI MALAYSIA PAHANG JUDUL: DESIGN ANALYSIS OF EXTERIOR CAR BODY PART SESI PENGAJIAN: 2012/2013 Saya, BASTIAN WIBAR BIN MOMANG ( ) mengaku membenarkan tesis (Sarjana Muda / Sarjana / Doktor Falsafah)* ini disimpan di perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis ini adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi / badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) Alamat Tetap: LOT NO:304 BLOK B, KG PASIR PUTIH, 91008,JALAN SIN SAN, TAWAU,SABAH. (TANDATANGAN PENYELIA) IR. HAJI NIK MOHD ZUKI BIN NIK MOHAMED Tarikh: 25 JUNE 2013 Tarikh: 25 JUNE 2013 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

3 ii EXAMINER S APPROVAL DOCUMENT UNIVERSITY MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the thesis entitled Design Analysis of Exterior Car Body Part is written by Bastian Wibar Bin Momang with matrix number MH I have examined the final copy of this report and in my opinion; it is fully adequate in terms of scope and quality of the award of the degree of Bachelor of Engineering with Automotive Engineering. I herewith recommend that it be accepted in partial fulfillment of the requirements for the degree of Bachelor Engineering. Signature: Examiner: Mr. Luqman Hakim Bin Ahmad Shah Date:

4 iii SUPERVISOR S DECLARATION I hereby declare that I have checked this thesis, which written by Bastian Wibar Bin Momang and in my opinion, this project is adequate in terms of scope and quality of the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Signature: Name of Supervisor: Ir. Dr. Hj. Nik Mohd Zuki Bin Nik Mohamed Position: Supervisor Date:

5 iv STUDENT S DECLARATION I hereby declare that the work in this project is my own except for quotations and summaries which have been duly acknowledged. The project has not been accepted for any degree and is not concurrently submitted for award of another degree. Signature: Name: Bastian Wibar Bin Momang ID Number: MH09041 Date:

6 viii TABLE OF CONTENTS EXAMINIRER S APPROVAL DOCUMENTS SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS Page ii iii iv v vi vii viii xi xii xiv xv CHAPTER 1 INTRODUCTION 1.1 Background of the Study Problem Statement Objectives of the Study Scopes of the Study Thesis Organization 4 CHAPTER 2 LITERATURE REVIEW 2.1 Stress and Strain Stress and Normal Strain Hooke s Law; Modulus of Elasticity The Stress Strain Curve Finite Elements Analysis (FEA) The Roles of Finite Elements Simulation ALGOR Software Mechanical Event Simulation (MES) Mesh of Finite Element Analysis Stress Analysis 14

7 ix 2.3 Defects in Surface of the Car Panels Springback Shock Line Skid Line Wrinkles Warping Crack 21 CHAPTER 3 RESEARCH METHODOLOGY 3.1 Introduction Stage 1: Literature Review Stage.2: Model Preparation and Machine Set-Up Combine the Subgroup Changes to IGES file Stage 3: Design and Assemble Design Characteristics Stage 4: Analyzing Using FEM Simulation Static Simulation Analysis Description Stage 5: Analysis of Simulation Results 37 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction Static Simulation at the All Surface Areas Strain Simulation at the All Surface Stress Simulation at the All Surface Displacement Simulation at the All Surface Comparison of the Front Fender Simulation for All Surface Areas Strain Analysis of the All Surface Stress Analysis of the All Surface Displacement Analysis of the All Surface Static Simulation at Selected Surface Area Strain Simulation of Selected Surface Stress Simulation of Selected Surface Displacement Simulation of Selected Surface 52

8 x 4.5 Comparison of the Front Fender Simulation for Selected Surface Area Strain Analysis of Selected Surface Stress Analysis of Selected Surface Displacement Analysis of Selected Surface CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 5.1 Conclusion Recommendations 59 REFERENCE 61 APPENDICES 63 A Simulation Data 63 B Analysis Data 68

9 xi LIST OF TABLES Table No. Title Page 3.1 Dimension of Front Fender Panel Properties of Mild Steel Properties of Static Simulation 37

10 xii LIST OF FIGURES Figure No. Title Page 2.1 Various regions and points on the stress-strain curve Mesh of FEA Spring back Shock line defect Skid line defect Wrinkles problem Warping defect Drawing crack Stretching crack Elongation flange crack Flexural crack Research Methodology flow diagram D Scanner Machine Cabling Diagram Front Fender after scanning process Front Fender Model after editing and repair in IMEdit Creating NURBS from Curve Network for front fender surface Front Fender SOLIDWORKS model Force applied at all surface area of front fender panel Force applied in the selected surface area of front fender panel Front Fender after meshing process Strain analysis of Proton Iswara of the all surfaces Strain analysis of Honda EG of the all surfaces 39

11 xiii 4.3 Strain analysis of Proton Saga of the all surfaces Stress analysis of Proton Iswara of the all surfaces Stress analysis of Honda EG of the all surfaces Stress analysis of Proton Saga of the all surfaces Displacement analysis of Proton Iswara of the all surfaces Displacement analysis of Honda EG of the all surfaces Displacement analysis of Proton Saga of the all surfaces Comparison of strain analysis of the all surfaces Comparison of stress analysis of the all surfaces Comparison of displacement analysis of the all surfaces Strain analysis of Proton Iswara at selected surface Strain analysis of Honda EG at selected surface Strain analysis of Proton Saga at selected surface Stress analysis of Proton Iswara at selected surface Stress analysis of Honda EG at selected surface Stress analysis of Proton Saga at selected surface Displacement analysis of Proton Iswara at selected surface Displacement analysis of Honda EG at selected surface Displacement analysis of Proton Saga at selected surface Comparison of strain analysis of selected surface Comparison of stress analysis of selected surface Comparison of displacement analysis of selected surface 56

12 xiv LIST OF SYMBOLS σ P A ε δ L E n value True Stress, Local Stress Pressure Area Normal stain Deformation Length Modulus of Elasticity Exponent Hardening % Percentage ρ Density

13 xv LIST OF ABBREVIATIONS 3D CFD CAE FEA FEM MES SI Three Dimensional Computational Fluid Dynamics Computer Aided Engineering Finite Element Analysis Finite Element Method Mechanical Event Simulation Standard International