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REF. Dr No. SE-01-1001

MODEL : 48’ 15T LOW BED TRAILER

TRAILER OVERALL DIMENSIONS:

OVER ALL LENGTH : 14675 MM (48’)
OVER ALL WIDTH : 2600 MM
HEIGHT OF THE TRAILER BED
FROM GROUND LAVAL : 650 +/- 25 MM (UNLADEN)
WHEEL TRACK : 2435 MM
SPRING CENTERS : 1900 MM

CHASSIS FRAME :
MAIN MEMBER : ROLLED BEAM ISMB 300x150 & 250x125
CROSS MEMBERS : ROLLED CHANNEL ISMC 125x65
OUT RIGGERS : PRESSED BOX SECTION 125x65x6 THICK
PLAT FORM : 3.15 MM MS SHEET

KING PIN :
2” DIA AS PER IS:6763(PART 1)-1987, EN 24 FORGED MATERIAL OR SAE/SMMT
EQUVELENT STANDRED. KING PIN LOAD AT THE TRAILER 12T

AXLE :
TWO AXLES OF LOAD RATING 13000KG EACH ARE PROVIDED IN DOUBLE
SUSPENSION ARRANGEMENT. AXLES ARE MADE OUT OF EN-8 ALLOY STEEL
HAVING PRECISION FINISHED BEARING JOURNALS. FITTED WITH TAPER ROLLER
BEARINGS, AXLES ARE DESIGNED TO WITHSTAND RUGGED CONDITIONS OF
OPERATION.

SUSPENSION :
DOUBLE AXLE SUSPENSION COMPRISES OF 4 NOS, LEAF SPRINGS OF ADEQUATE
CAPACITY, THE SPRINGS ARE MADE OUT OF EN-45 SPRING STEEL MATERIAL.

BREAKES :
BREAKES PROVIDEED WORKS ON TWIN LINE AIR PRESSURE BRAKE SYSTEM
INTERNAL EXPANDING QUICK CHANGE ‘S’- CAM TYPE OF SIZE 15.5” x 5”

WHEELS :
4 NOS. H 7.0 x 20

TYRES :
4NOS. 10.00 x 20 - 16 PR NYLON TYRES

FRONT SUPPORT :
IT CONSIST OF TWO NO. OF LEGS EACH CONSISTING OF TWO TUBES, ONE
SLIDING INSIDE THE OTHER THE MATERIAL OF THE TUBE IS MILD STEEL.

DESIGN CALCULATIONS – Tandem Axle Lowbed Semi

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Calculation of Main Member :

Pay load = 12.8 T

Chassis wt = 12.2 T
Design load = 25.0 T
U.D.L. Due to Design Load = 25000 / 14675 = 1.70 Kg/mm

The loading distribution is as shown in fig. given below.

Calculation for Reaction Taking moment About King Pin ‘K’,

RA x 10000 = 25 x (7337.5 - 675)

RA = 16.65 T
RK = 25 – 16.65 = 8.35 T
Load on Axles = RA + Dead Wt of Axles
= 16.65 + (0.45x2)
= 17.55 T

Calculation for BM:

BM at ‘K’ = 675 x 675 x 1.70 = 0.3873 x106 Kg

2
BM at ‘C’ = 7337.5 x 7337.5 x 1.70 – [8350 x (7337.5-675)] = 9.8688 x 106 Kg mm
2
BM at ‘A’ = 4000 x 4000 x 1.70 = 13.6 x106 Kg mm
2
Let the B.M is maximum at a distance of ‘X’ from front,
In this case Bmax = X2 x 1.70 - (X - 675) x 8350
2
To have BM max the dBmax should be zero
dx
 dB max = 0 = d (0.85 X2 – 8350 X – (8350 x 675)
dx dx
 0.85 x 2X – 8350 = 0
 X = 8350 / 1.70 = 4912 mm

BM at 4912 mm from front we have

= (4912 x 4912 x 1.70) – [8350 (4912 – 675)] = 14.87 x106 Kg-mm
2

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Main Member Material Sailma 350 HI

Yield stress of Sailma 350 HI is 350 MPa = 35.714 Kg/mm2
Factor of Safety 2
Allowable stress = 35.714 = 17.85Kg/mm2
2
Section selected – ISMB 300x140:

ZX (Section modulus) = 140 x 3003 – 132.5 x 275.23 = 0.5657 x 106 mm3

6 x 300
Max Stress induced = 14.87x106 = 13.14 Kg/mm2
6
2 x 0.5657x10
As the STRESS INDUCED is less than the allowable stress of 17.85 Kg/mm2, so the section is
safe.

Now checking at reduced section. The main member is as shown in figure:

The section up to 1420 mm is straight after it tapers from 250 to 300mm in a length of 800 mm.

5mm plate flitching is done in a length of 800mm starting from a distance of 1140mm from front.
BM at 1140mm from front: = 1140 x 1140 x 1.70 – 8350 (1140-675) = 2.778 x 106 Kg mm
2
Zx (Fig 1) = 125 x 2503 – 118.1 x 2253 = 0.405 x 106 mm3
6 x 250
Stress induce = 2.778 x 106 Kg mm = 3.43 Kg/mm2
6 3
2 x 0.405 x 10 mm
BM at 1420mm from front = 1420 x 1420 x 1.70 – 8350 (1420 - 675) = 4.507 x 106 Kg mm
2
Zx at 1420 mm (Fig 2) = 125 x 2503 – 107 x 2223 = 0.521 x 106 mm3
6 x 250
Stress induced = 4.507 x 106 Kg mm = 4.32 Kg/mm2
6 3
2 x 0.521 x 10 mm

DESIGN CALCULATIONS – Tandem Axle Lowbed Semi

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BM at 2220mm from front = 2220 x 2220 x 1.70 - 8350 (2220 – 675) = 8.71 x 106 Kg mm
2
Zx = 140 x 3003 – 122 x 2723 = 0.736 x 106 mm3
6 x 300
Induced Stress BM = 8.71 x 106 = 5.91 Kg/mm2
Zx (2 x 0.736 x 106)
As the INDUCED STRESS at all three points are less than the allowable stress of 17.85
Kg/mm2, section is safe.

Design Calculation for cross members:

The design load of 25 T is acting over an area of 14675mm x 2600mm. Main members and cross
members resist this load. The load on each cross member is proportional to its distance to the
adjacent cross members.

Intensity of load acting over loading area = 25000 / (14675 x 2600)

= 0.00065 Kg/mm2
Maximum spacing of cross member = 1200 mm
Equivalent line load over the cross member = 1200 x 0.00063 = 0.78 Kg/mm

The cross members are welded to the main members. For calculation purpose the main members
are neglected and the cross member and our riggers are assumed to be overhanging beam
supported by the longitudinal main members as shown below.

Reaction at the support in Main member = 0.78 x 2460/2 = 959.4 Kg

Bending moment at support (A & B) = 0.78 x 530x 530/2 = 0.1095 x 106 Kg mm
Bending Moment at center (C) = 0.78 x 1230 x 1230 - (959.4 x 1400/2)
2
= 0.0815 x 106 Kg mm
Maximum Bending Moment = 0.1095 x 106 Kg mm
Material selected for cross member is IS: 2062
Permissible Bending stress = 10.5 Kg/mm2
Section selected is ISMC 125 x 65

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From table Section modulus Zx of ISMC125 = 0.067 x 106 mm3

Stress induced = 0.1095 x 106 = 1.634 Kg/mm2

0.067 x 106
As the STRESS INDUCED is less than the allowable stress of 10.5 Kg/mm2 hence safe.

Design calculation for axle:

Two axles are provided made out of EN8 alloy steel Yield strength of 35.71 Kg/mm2.
Taking factor of safety of 2.5 on yield strength,
Allowable stress = 14.28 Kg/mm2
U.T.S. of EN 8 = 54 Kg /mm2
Allowable stress with factor of safety 4 = 13.5 Kg/mm2
Axle assembly Weight = 450 x 2 axles = 900 Kg
Load per spring = (16650 + 900)/4 = 4387.5 Kg
Wheel track = 2366 mm
Spring centers = 1860 mm

Max. B.M. will occur at spring centers:

Max. B.M. at A & B = 4387.5 x 253 = 1.11 x 106 Kg mm
Section modulus of axle at spring centers,
Zx =  d3 =  x 1103 = 0.13 x 106 mm3
32 32
Max. Stress developed = Max. BM. /Zx = (1.11 x 10 ) / (0.13 x 106)
6

= 8.54 Kg/mm2
Since the MAXIMUM STRESS developed is less than the allowable stress of 13.5kg/mm2,
axle is safe.

Checking the axle at reduced sections:

At section ‘A-A’:
B.M = 4387.5 x 61.6 = 0.27 x 106 Kg mm
Section modulus (Zx) = /32 x 78.7 3 = 0.0478 x 106 mm3
Bending stress developed = 0.27 x 106 = 5.648 Kg/mm2

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0.0478 x 106
At section ‘B-B’:
B.M = 4387.5 x 101.1 = 0.4435 x 106 Kg mm
Section modulus (Zx) = /32 x 82.63 = 0.0553 x 106 mm3
6
Bending stress developed = 0.4435 x 10 = 8.02 Kg/mm2
0.0553 x 106
Since the MAXIMUM BENDING STRESS developed is less than the allowable stress of
13.5kg/mm2, axle is safe.

Design calculation for suspension:

Material of spring: Spring steel EN 45 confirming to BS: 970-1955.
Working stress (F) = 5500 Kg/cm 2
No. Of leaves (n) = 12
Effective span (L) = 882 mm = 88.2 cm
Width of leaf (b) = 76.2 mm = 7.62cm
Thickness of leaf (t) = 11.11 mm = 1.111 cm
Therefore capacity (P) = 2 x f x n x b x t x 2 /(3 L)
= 2 x 5500 x 14 x 76.2 x 1.111x 2 / (3 x 88.2)
= 5474 Kg
There are 4 numbers of springs are used in double axle suspension unit. The maximum static load
on the suspension unit is 16650 Kg
Load per spring = 16650 / 4 = 4162.5 Kg per spring
Allowable load = 5474 Kg per spring
Hence spring design is safe.

Design calculation for equalizer arrangement:

Load on each spring = 16650/4 = 4162.5 Kg
Load on equalizer = load on each spring = 4162.5 Kg
Load on equalizer bracket is shown in fig below.

Maximum bending moment,

Bmax = 2081.25 x 225 = 0.468 x 106 Kg mm
Section modulus (Zx)
The cross section of equalizer welded assembly is as shown in fig below:

DESIGN CALCULATIONS – Tandem Axle Lowbed Semi

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A1 = 2(11x10) = 220 mm2 Y1 = 5.5 mm from top

2
A2 = 2(114x8) = 1824 mm Y2 = 51 mm from top
A3 = 2(67.75x10) = 1355 mm2 Y3 = 124.875 mm from top
Y = A1xY1 + A2xY2 + A3xY3
A1 + A2 + A3
= 220 x 5.5 + 1824 x 51 + 1355 x 124.875
220 + 1824 + 1355
= 77.5 mm from top
Ymax = 158.75 - 77.5 = 81.25 mm
Moment of inertia of cross section (I) = I1 + (A1 x H12) + I2 + (A2 x H22) + I3 + (A3 x H32)
= 2(10 x 113) + (220 x 722) + (114 x 803) – (114 x 643)
12 12
+ (1824 x 26.5 ) + 2(10 x 67.75 ) + 1355 x (47.3752)
2 3

12
6 4
= 8.356 x 10 mm

Z= I = 8.356 x 106 = 0.1029 x 106 mm3

Ymax 81.25
Max bending stress induced = 0.468 x106 = 4.55 Kg/mm2
0.1029 x106
MAX. BENDING STRESS INDUCED is less than the allowable stress of 10 Kg/mm2, hence
equalizer welded assembly is safe at this section.

Calculations for equalizer shaft:

Load on each spring = 16650/4 = 4162.5 Kg
The equalizer welded assembly is supported by the M.S shaft in the central spring hanger bracket.
Load distribution on the shaft is as shown below:

Checking the shaft for bending:

U D LW = 4162.5 /114 = 36.51 Kg/mm

Max. BM = 2081.25 x 95 – 35.85 x 572 = 0.139 x 106 Kg mm.

2
Section modulus (Zx) = /32 x d 3
= /32 x 63.53 = 0.0251x106 mm3.
6
Bending stress = 0.139 x 10 = 5.54 Kg/mm2
0.0251 x 106
Since the BENDING STRESS is less than the allowable stress of 10 Kg/mm2, shaft is safe.

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Checking the shaft for double sheer:

Fs = load / area = 4162.5 = 0.657 kg/mm2
[2 x ( x 63.52]

Since the STRESS induced is less than allowable stress of 10 Kg/mm2 for rolled section, shaft
is safe.

Design calculation for kingpin:

Kingpin to be fitted on to the trailer is as per the BIS/SAE/SMMT standards.
The kingpin size is 50 x 73mm (2” x 2.7/8”) as per IS: 6763(part1)1987. The kingpin is designed
to withstand a draw bar pull of load ‘P’ on force and aft direction (27215 Kg = 27.215 T)
Material is EN 24 suitably heat treated to give hardness of 269 BHN to 321 BHN.

Ultimate tensile strength of material = 94.7 Kg/mm2

For repeated cycles we will take Permissible Bending Stress = 15 Kg/mm2 and Permissible Sheer
Stress = 9 Kg/mm2

To check for bending:

Bending stress, Fb = BM. /Zx
Now bending moment B.M = 27215 x 17.5 = 476.26 x 103 Kg mm
Section modulus, Zx = /32 x d 3
= /32 x 733 = 38.19 x 103 mm3
Fb. (bending stress) = 476.26 x 103 / 38.19 x 103 = 12.47 kg/mm
Since the BENDING STRESS is less than the Permissible Stress of 15kg/ mm2, the kingpin is
safe in bending.

To check for sheer:

Sheer stress, T = Load
C/s area of kingpin
= 27215 = 6.5 Kg/mm2
( /4) x 732
Since the SHEER STRESS INDUCED is less than the Permissible Shear Stress of 9 Kg/mm2,
the kingpin is safe for shearing.

Tractive force of king pin, F =  x w

(Where ‘ ‘is the coefficient of friction between road and tyres, generally taken as 0.3 and w =
GLW of trailer)
F = 0.3 x 26650 = 7890 Kg which is less than the above load P,
hence kingpin is safe.

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Brakes calculation:
R.T.O. regulations - At 20mph (32 Km/h) vehicle fully loaded should stop within 14.5 meters from
the point of application of brakes
Initial velocity (u) = 32Km/h = 8.889 m/sec.
Final velocity (v) =0
Distance traveled (s) = 14.5 meters
From the laws of motion:
v2 - u2 = 2 x f x s
0 - (8.89892) = 2 x f x 14.5
Force (f) = (8.89892) = 2.7246 m/sec2
29
Load on rear axles = 16.35T + 0.9T = 17.55T
Design load per axle = 17550/2 = 8775 Kg
No. of brakes per axle =2
Load per brake = 4387.5 Kg
Required retarding force = load per brake x f
g
= 4387.5 x 2.7246 = 1218.57 Kg
9.81
Road wheel diameter of tyre (10.00 x 20 x 16 ply) = 1094mm = 109.4 cm
Required retarding torque = retarding force x rolling radius of tyre
= 1218.57 x 54.7 = 66,655.8 Kg-cm ………………. (1)
Brake size used is 15.5” x 4.5” (39.4cm x 11.5cm)
Brake drum diameter = 394 mm = 39.4 cm
Brake lining area = 453.1 cm2
Lining material used is DON HF 7 or S/A 63 S having allowable compressive stress 12.0 Kg/cm 2,
Co-efficient of friction ( ) = 0.4
Lining drag =12.0 x 0.4 = 4.8 Kg/cm2
Available brake drum torque = brake lining drag x Lining area x Brake drum radius
= 2 x 4.8 x 453.1 x 39.4/2 = 85,690 Kg-cm ...………… (2)
From (1) & (2) it is seen that available brake drum torque is more than the required retarding
torque. Hence brakes are safe.

Design calculation for tyres:

Size of tyres used = 10.00 x 20 x 16 ply
Capacity of tyre @ 32 Km = 3050 Kg (As per ITTAC Data manual)
And at cold pressure 725 Kpa.
Total load on tyres = 16650 + 900 (Axle Wt) = 17550 Kg
No. of tyres used =4
Actual Load on each tyre = 17550 = 4387.5 Kg.
4
As tyres are designed for 50% excess load, Load bearing capacity of 10.00x20-16 PR tyres
= 1.5 x 3050 = 4575 kg each.
As designed capacity of tyre is more than the actual load on tyres, hence tyres are safe.

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Front support calculation :

There are two tube type landing legs, provided at a distance of 2875mm from front. The reaction
and bending moment calculation are given below.

Taking moment about – L

RA x 7800 = 25 x (7337.5 – 2875)
RA = 14.30 T
RL = 10.70 T
Actual load coming on landing legs is 10.70T ***

Design of leg on column principle:

 Considering top end fixed and bottom end as free.
 Considering the inner leg, having the lower cross section area, for height of 1100mm in fully
extended condition i.e., L = 1100 mm.
The cross section of inner leg is as shown in fig.

Using Ranking Formula for Crippling load, Pc = Fc x A

1 + C (L/K) 2
Where,
Fc = compression stress for MS = 33 Kg/mm2
A = Area of cross section = 2350 mm2 (from table)
C = Ranking constant = 1
7500 x 0.25
Where 0.25 is the coefficient of end condition

K = least radius of gyration = Moment if inertia (I)

Cross sectional area (A)

= (100 x 1003) – (90.6 x 90.63) = 34.01 mm

12 x 2350

Substituting these values in formula for crippling load,

Pc = 33 x 2350 = 65.336 Kgs.
2
1 + (1/1875) x (1100/34.01)

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Allowable load = Crippling load / factor of safety.

For steady load factor of safety =4
Therefore allowable load = 49775 = 12443 Kg
4
Therefore allowable load per leg = 12443 = 6221.5 Kg
2
The allowable load of 6221.5kg is more than the actual load per leg of 10700 = 5350 Kg. ***
2
Hence front support leg is safe.

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
***this load is transferred on the legs when tractor is detached from the trailer.

DESIGN CALCULATIONS – Tandem Axle Lowbed Semi

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