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Finite element analysis based design of cross-member beams for heavy trucks
2003 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The thesis presented here is a project aiming to develop a new cross-member beam consisting of two or more parts, unlike the current design which is made from a single piece. This is to decrease the manufacturing cost of the existing type of cross member-beam. In addition, the study aims to increase Ferruform’s understanding of chassis components and their structural behavior for future product development. The reference cross-member beam is a patented Scania beam designed primarily for loads along the side member beams. The reference beam utilizes a design where the force-flow-lines from the side-member beams meet in an X like shape. This patented technique facilitates a compact design while maintaining a strong structural part in the truck chassis. Furthermore, the beam design is composed of a single part, contrary to conventional types composed of three or more. This feature decreases manufacturing and assembly costs. While decreasing manufacturing costs the design is very expensive in terms of material waste, 56% of the original steel sheet is wasted. Shipping the beams is also expensive as the beams are packed with ten other beams in Euro pallets, and shipped to final destination for assembly. The concept beams developed in the project have focused on decreasing the material waste and increasing the number of beams shipped on each pallet. To increase the number of beams in each shipment the concepts have utilized riveting to join the parts at the assembly plant where the cross-members are also mounted to the frame. The project has primarily treated solid modeling in I-DEAS and structural analysis using the finite element method (FEM). The FEM simulations throughout the thesis have been used to predict the behavior of the designs, allowing rapid improvements to be made. The most feasible concept has proven to both decrease the material costs and the shipping costs. Additionally, the concept can be designed to be stiffer than the reference beam, however, this depends on the number of rivets used to join the two parts. One drawback is that the assembly cost associated with riveting increases the total cost of the concept. To maintain the structural integrity of the reference beam in all directions numerous rivets have to be used. In conclusion, the results from the study are that the developed concepts have greater structural properties than those of the reference beam, but at a slightly higher cost. Ferruform needs to determine if the increased total cost for the beam can be justified by the increased structural properties. The benefits of a stiff design compared to a weaker design also need to be determined. While a stiffer design starts to plastically deform when subjected to a specific displacement, a weaker design still behaves linearly. On the other hand, a weaker design would start to plastically deform at a lower load than a stiffer one. To better compare the beam designs, more precise requirements are needed to determine the required stiffness.

Place, publisher, year, edition, pages
2003.
Keyword [en]
Technology, Finite Element Analysis, Cross-Member Beams, Heavy Trucks
Keyword [sv]
Teknik
Identifiers
URN: urn:nbn:se:ltu:diva-53918ISRN: LTU-EX--03/086--SELocal ID: ae68cfc9-8903-4c08-aafa-f9e9a5719873OAI: oai:DiVA.org:ltu-53918DiVA: diva2:1027295
Subject / course
Student thesis, at least 30 credits
Educational program
Mechanical Engineering, master's level
Examiners
Note
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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  • apa
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