“Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO.1: INTRODUCTION

Chassis is a French term and was initially used to denote the frame parts or Basic
Structure of the vehicle. It is the back bone of the vehicle. A vehicle with out body is called
Chassis. The components of the vehicle like Power plant, Transmission System, Axles,
Wheels and Tyres, Suspension, Controlling Systems like Braking, Steering etc., and also
electrical system parts are mounted on the Chassis frame. It is the main mounting for all the
components including the body. So it is also called as Carrying Unit.

1.1. Function of Chassis :

1. To carry load of the passengers or goods carried in the body.
2. To support the load of the body, engine, gear box etc.,
3. To withstand the forces caused due to the sudden braking or acceleration .
4. To withstand the stresses caused due to the bad road condition.
5. To withstand centrifugal force while cornering.
1.2. Chassis material :
Most cars on the street are using steel as the material of choice to build the chassis,
this include monocoque and traditional ladder frame chassis. Steel found it’s way to cars that
demands high durability and reliability such as passenger cars, vans, trucks, and SUVs. High
performance cars use aluminum in least structural parts of the chassis like middle roof brace
and front and rear hangover section (this doesn't applicable to older high performance cars).
However, Supercar and Hypercars manufacturers utilize either full CF chassis for their top of
the line model (488, Aventador, CCX) or Aluminum-CF combo on their “affordable” model
(California, Huracan, etc.)
Due to the fact, that the mass of a car influences all driving resistances, excepted
aerodynamic drag forces, lightweight design plays an important role for increasing driving
performance and reducing fuel consumption.
In general, different materials are used in automotive body and chassis structure: Steel,
high-strength steel, aluminum, plastics (e.g. as body panels) and carbon fibre. The decision,
which material is the optimal one for a certain car model is influenced by different factors,
e.g. design-related aspects, safety aspects, lightweight requirements, connection technology,
number of production per year, existing production facilities, investment costs, costs per unit,
and life-cycle related aspects.

DEPARTMENT OF MECHANICAL ENGINERING 1

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

As a rough estimation, the following lightweight potential is provided by alternative

materials in comparison with standard steel: high-strength steel (10% weight reduction),
aluminum (30-40% reduction), carbon fibre (50% reduction). Out of cost, production and
safety reasons (e.g. crash behavior), combinations of the materials are used in some BiW
design, which leads to reduced reduction of lightweight potential.
Different materials have varying deformation behavior, which influences the
characteristics in case of a crash. In this context, steel has some advantages, but also
aluminum can be used for bumbler and crash box design. Carbon fibre are topic of research in
this area.

1.3. Requirement of bodies for various type of vehicle :

The body of the most vehicle should fulfill the following requirements:
1. The body should be light.
2. It should have minimum number of components.
3. It should provide sufficient space for passengers and luggage.
4. It should withstand vibrations while in motion.
5. It should offer minimum resistance to air.
6. It should be cheap and easy in manufacturing.
7. It should be attractive in shape and colour.
8. It should have uniformly distributed load.
9. It should have long fatigue life
10.It should provide good vision and ventilation.

DEPARTMENT OF MECHANICAL ENGINERING 2

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO.2: LITERATURE REVIEW

Sr Title Author Findings

No /Publication
This paper involves
1 Vibration Analysis of Vehicle Y.S. Rajput importance in the
frame /IJERA development of off-road
racing vehicle for the
value of dynamic
analysis under severe
uneven loading. The
dynamic analysis is
carried out by the finite
element analysis thereby
predicting failure modes
of the vehicle frame
under vibration analysis.
This work investigates
the vibration
characteristics of the
frame including the
natural frequencies and
mode shapes.
Chassis frame must be
2 Static Analysis, Design Madhu Ps/IJERA strong enough to resist
Modification and Modal Analysis the shock, twist,
of Structural Chassis Frame vibration and other
stresses. The objective
of present is to determine
the maximum stress,
maximum deflection and
to recognize critical
regions under static
loading condition.
The results obtained like
maximum shear stress,
Von-mises stress and
maximum deflections are
used for improving
design modification.
Through modal analysis,
natural frequencies and
corresponding vibration
mode shapes of the
structure are obtained.
3 Modal Analysis of Titan Cantilever Pavol In this paper are given
Beam Using ANSYs and Lengvarský/AJME basic steps of the modal
SolidWorks analysis simulation. The
modal analysis is carried
out on

DEPARTMENT OF MECHANICAL ENGINERING 3

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

the titan cantilever beam.

. The cantilever beam
was fixed on one end and
all degrees of freedom
on this end were taken,
beam
cannot move and rotate.
Mode shapes and natural
frequencies are
computed
with numerical
formulation of the direct
solver including the
block Lanczos method.
In this study modal
4 Modal Analysis and Harmonic Dr. C. M. analysis
Response Analysis of a Crankshaft Ramesha/IJETAE of a single cylinder
engine crankshaft is
carried out and first
twelve modes of
vibration are extracted
for free-free as well as
constrained boundary
conditions. The mode
shapes are observed
which provide a
comprehensive picture of
deformations occurring.
Harmonic response was
also studied by
subjecting the
component to an exciting
frequency range of 0 –
5000 Hz .

Carry out the static

5 Research on Optimal Design and Kaifa analysis of the frame
Modal Analysis of the Frame. Lian/ICAITA under different working
conditions and put
forward four kinds
scheme of the
improvement of the
beam, longitudinal beam
and traction plate.
Besides, carry out the
modal analysis of the
frame, get the natural
frequency and vibration
mode of the frame, to
provide the driver with a

DEPARTMENT OF MECHANICAL ENGINERING 4

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

reliable theoretical basis

to avoid the resonance.
6 Modal analysis of plane frame Mohammed The objective of this
Siraj/IJERT paper is to study the
vibration, frequency and
mode shape ofplane
frames. Formulation of
stiffness matrix and mass
matrix are to be done
using direct stiffness
method.
7 Static and modal analysis of drive Baswaraj/IJSRET In present work an
shaft using steel and high attempt has been to
performance estimate deflection,
polymer composites comparison stresses under subjected
loads & natural
frequencies using FEA,
for light duty drive shaft
and Heavy duty Drive
shaft using different
materials like High alloy
steel, glass/epoxy,
carbon/epoxy,
Kevlar/epoxy and
carbon-Kevlar/epoxy.
For Light duty drive
shaft, the usage of
composite material
(Carbon Kevlar/Epoxy)
has resulted to
considerable amount of
weight saving in the
range of 79.74% when
compared to
conventional steel drive
shaft. For Heavy duty
drive shaft, the usage of
Carbon-
Kevlar/Epoxy has
resulted to considerable
amount of weight saving
in the range of 81.3%
when compared to
steel drive shaft.
8 Static and Vibration Analysis of an Study of the static and
Aluminium and Steel Bus Frame vibratory behavior would
be very decisive. In this
article, two types of
analysis are carried out.
First is the modal

DEPARTMENT OF MECHANICAL ENGINERING 5

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

analysis to determine the

natural frequencies and
the mode shapes using a
developed dynamic
model of the bus.
Because if any of the
excitation frequencies
coincides with the
natural frequencies of the
bus frame, then
resonance phenomenon
occurs. This may lead to
excessive deflection,
high stress concentration,
fatigue of the structure
and vehicle discomfort.
In this case, the results
analysis shows that the
natural frequencies are
not affected by the
change of material. The
second type of analysis
is the linear static stress
analysis to consider the
stress distribution and
deformation frame
pattern under static loads
numerically.
9 Design and Analysis of chassis Amrendra Kumar Truck chassis is the
frame Singh/IJRE structural backbone of
any vehicle. The main
function of the truck
chassis is to carry the
goods and payload
placed upon it. The
chassis frame has to bear
the stresses developed
and deformation occurs
in it and that should be
within a limit. This paper
presents the study of the
stress developed in
chassis as well as
deformation of chassis
frame. The stress and
deformation has been
calculated for the chassis
frame and the analysis
has been done for the
validation on the chassis

DEPARTMENT OF MECHANICAL ENGINERING 6

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

frame.
10 Structural Analysis of Patel Vijaykumar The chassis serves as a
V/IJERT frame work for
Automotive Chassis
supporting the body and
Frame and Design different parts of the
Modification for Weight automobile. Also, it
Reduction should be rigid enough
to withstand the shock,
twist, vibration and other
stresses. Along with
strength, an important
consideration in chassis
design is to have
adequate bending
stiffness for better
handling characteristics.
So, maximum stress,
maximum equilateral
stress and deflection are
important criteria for the
design of the chassis.

DEPARTMENT OF MECHANICAL ENGINERING 7

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO.3: PROBLEM DEFINATION

It identifies that the work should focus on vibration aspects of chassis design. Therefore, the
modeling and analysis of truck chassis and study of the natural frequencies is aimed in the
present study.

The project objectives are as follows:

1. Determination of the modal frequency and mode shape of the chassis by using modal
analysis.
2. To study the dynamic behaviour of the truck chassis for various material .
3. To improve chassis design by reduction of the weight of chassis.
4. Determination of the modal frequency and mode shape of the Chassis for modified design
by using modal analysis.

DEPARTMENT OF MECHANICAL ENGINERING 8

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO.4: METHODOLOGY

Introduction to modal analysis

Geometry development using CAD

Modal analysis of Chassis using FEA

Design modification

Modal analysis of modified design

mooptimised

Compare results

Figure 4.1. Methodology

4.1 . Introduction to modal analysis :

Modal analysis is the study of the dynamic properties of systems in the frequency
domain. Examples would include measuring the vibration of a car's body when it is attached
to a shaker, or the noise pattern in a room when excited by a loudspeaker.

Modern day experimental modal analysis systems are composed of 1) sensors such
as transducers (typically accelerometers, load cells), or non contact via a Laser vibrometer,
or stereo photogrammetric cameras 2) data acquisition system and an analog-to-digital
converter front end (to digitize analog instrumentation signals) and 3) host PC (personal
computer) to view the data and analyze it.

Classically this was done with a SIMO (single-input, multiple-output) approach, that
is, one excitation point, and then the response is measured at many other points. In the past a
hammer survey, using a fixed accelerometer and a roving hammer as excitation, gave a MISO
(multiple-input, single-output) analysis, which is mathematically identical to SIMO, due to
the principle of reciprocity. In recent years MIMO (multi-input, multiple-output) have become
more practical, where partial coherence analysis identifies which part of the response comes

DEPARTMENT OF MECHANICAL ENGINERING 9

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

from which excitation source. Using multiple shakers leads to a uniform distribution of the
energy over the entire structure and a better coherence in the measurement. A single shaker
may not effectively excite all the modes of a structure. Typical excitation signals can be
classed as impulse, broadband, swept sine, chirp, and possibly others. Each has its own
advantages and disadvantages.

The animated display of the mode shape is very useful to NVH (noise, vibration, and
harshness) engineers. The results can also be used to correlate with finite element
analysis normal mode solutions.

4.2 .Geometry developed using CAD :

Computer-aided design (CAD) is a computer technology that designs a product and

documents the design's process. CAD may facilitate the manufacturing process by transferring
detailed diagrams of a product's materials, processes, tolerances and dimensions with specific
conventions for the product in question.
The design of the chassis starts with the definition of the piston geometry using 3D CAD
software. This 3D CAD geometric model is then imported to FEA software and analysed
under the predicted service conditions before anything is made. That speeds up the design and
testing process, reduces the lead time to create new chassis designs, and produces a better
product. The idea behind finite analysis is to divide a model chassis into a fixed finite number
of elements. Analysis of the chassis is done to optimize the stresses and minimize the weight
using ANSYS.
The mathematical model of optimization is established firstly, and the FEA is carried
out by using the ANSYS software. Based on the analysis of optimal result, the stress
concentrates on the chassis has become evaluate, which provides a better reference for
redesign of chassis.

Figure 4.2.1. CAD model of chassis

DEPARTMENT OF MECHANICAL ENGINERING 10

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

4.3. Modal analysis of chassis :

Steps involve in modal analysis (ANSYS workbench )

4.3.1. Define material properties :

Sr No Material Density Youngs Poissons ratio

(Kg/m3) modulus
(GPa)

1 Stainless steel 770 193 0.3

2 E glass polyster 2100 34 0.3
resin composite

3 High alloy steel 7900 210 0.3

Table 4.3.1 Material properties

4.3.2. Meshing

Figure 4.3.1. Meshing

DEPARTMENT OF MECHANICAL ENGINERING 11

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

Mesh quality check :

Sr. no. Mesh quality parameter Required Achieved

1 Skewness <0.7 0.3456
2 Jacobian Ideal value 1 1.0238
3 Warping <30, Ideal value 0 0
4 Aspect ratio <5 2.0955
5 Orthogonal quality >1 0.8032

Table 4.3.2. Mesh quality parameter static structural

4.3.3. Boundary condition :

A) Fixed support acting on chassis frame :

Figure 4.3.2. Boundary condition –Fixed support

DEPARTMENT OF MECHANICAL ENGINERING 12

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.3. Boundary condition –Fixed support

4.3.4. Mode shapes of chassis model :

Mode shapes can be defined as the shapes of the structure at different natural frequencies for
different material.

1. Stainless steel :

DEPARTMENT OF MECHANICAL ENGINERING 13

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.4. Mode shape 1

Figure 4.3.5. Mode shape 2

Figure 4.3.6. Mode shape 3

DEPARTMENT OF MECHANICAL ENGINERING 14

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.7. Mode shape 4

Figure 4.3.8. Mode shape 5

Figure 4.3.9. Mode shape 6

DEPARTMENT OF MECHANICAL ENGINERING 15

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

2. E glass polyster resin composite

Figure 4.3.10. Mode shape 1

Figure 4.3.11. Mode shape 2

DEPARTMENT OF MECHANICAL ENGINERING 16

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.12. Mode shape 3

Figure 4.3.13. Mode shape 4

DEPARTMENT OF MECHANICAL ENGINERING 17

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.14. Mode shape 5

Figure 4.3.15. Mode shape 6

DEPARTMENT OF MECHANICAL ENGINERING 18

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

3. Alloy steel :

Figure 4.3.16. Mode shape 1

Figure 4.3.17. Mode shape 2

DEPARTMENT OF MECHANICAL ENGINERING 19

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.18. Mode shape 3

Figure 4.3.19. Mode shape 4

DEPARTMENT OF MECHANICAL ENGINERING 20

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.3.20. Mode shape 5

Figure 4.3.21. Mode shape 6

DEPARTMENT OF MECHANICAL ENGINERING 21

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

4.4. Design modification :

The Design modification (Re-design) is the process of achieving some desired set of
specification which minimises the critical factors of model. While modifying the model, the
designer must have the knowledge about model, behaviour of the model under given loading
condition

Figure 4.4.1. Modified chassis CAD model

4.5. Modal analysis of Modified chassis:

1. Alloy steel :

Figure 4.5.1. Mode shape 1

DEPARTMENT OF MECHANICAL ENGINERING 22

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.5.2. Mode shape 2

Figure 4.5.3. Mode shape 3

DEPARTMENT OF MECHANICAL ENGINERING 23

“Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.5.4. Mode shape 4

Figure 4.5.5. Mode shape 5

DEPARTMENT OF MECHANICAL ENGINERING 24

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

Figure 4.5.6. Mode shape 6

4.6. Result and comparison :

4.6.1. Modal frequency for various material :

Mode number Modal frequency Modal frequency Modal frequency

(Stainless steel ) (E glass polyster (High alloy steel)
(Hz) resin composite) (Hz) (Hz)
1 1000 972.5 1033.6
2 1203.6 805.76 1243.1
3 1522.9 1221.7 1575.1
4 2202 1833.9 2360
5 2411.1 1948.1 2490.3
6 3165.1 2541.4 3272.9

Table 4.6.1. Modal frequency for various material

DEPARTMENT OF MECHANICAL ENGINERING 25

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

4.6.2. Deformation for various material :

Mode number Deformation Deformation Deformation

(Stainless steel ) (E glass polyster (High alloy steel)
resin composite)
1 1.68 3.3105 1.6648
2 1.72 3.2285 1.7065
3 2.5149 4.8349 2.4905
4 1.8440 3.53 1.8269
5 1.5537 2.9859 1.5388
6 2.793 5.3619 2.7648
Table 4.6.2. Deformation for various material
4.6.3. Modal frequency for present and modified design :(High alloy steel)
Mode number Modal frequency Modal frequency
(Present ) (Modified )
1 1033.6 1087.7
2 1243.1 1333.3
3 1575.1 1601.2
4 2360 2468
5 2490.3 2689.5
6 3272.9 3230.4
Table 4.6.3. Modal frequency for present and modified design

4.6.4. Deformation for present and modified design : (High alloy steel )

Mode number Deformation Deformation

(Present ) (Modified )
1 1.6648 1.6467
2 1.7065 1.6588
3 2.4905 2.4087
4 1.8269 1.8584
5 1.5388 1.5068
6 2.7648 3.229

Table 4.6.4. Modal frequency for present and modified design

DEPARTMENT OF MECHANICAL ENGINERING 26

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO 5. CONCLUSION

In this paper modification of chassis frame based on results and modal analysis of structure is
achieved. First modelling of structure done by CATIA and MODAL analysis is carried out
using following Ansys for 3 material , Stainless steel , E glass polyster resin composite, High
alloy steel is carried out Dynamic behaviour of chassis is studied for these 3 material
.Deformation of high alloy steel is low as compared to other 2 .. Modification of design is
carried out to reduce deflection of structure. Also weight optimization is achieved in modified
structure . Finally the natural frequency and corresponding vibration modes of modified
structure are found by modal analysis.

DEPARTMENT OF MECHANICAL ENGINERING 27

 “Modal analysis of vehicle chassis frame for various material and geometry” 2018

CHAPTER NO. 6 REFERENCES

[1] Y.S. Rajput, Vibration Analysis of Vehicle frame, IJERA

[2] Madhu Ps, Static Analysis, Design Modification and Modal Analysis of Structural Chassis
Frame, IJERA
[3] Pavol Lengvarský, Modal Analysis of Titan Cantilever Beam Using ANSYs and
SolidWorks, AJME.
[4] Dr. C. M. Ramesha., Modal Analysis and Harmonic Response Analysis of a Crankshaft ,
IJETAE
[5] Kaifa Lian., Research on Optimal Design and Modal Analysis of the Frame., ICAITA
[6 ] Mohammed Siraj , Modal analysis of plane frame, IJERT
[7] Baswaraj,”Static and model analysis of drive shaft using steel and high performance
polymer composite ”IJSRET
[8] Prakash Gadade and Arun L.R “Static and Vibration Analysis of an Aluminium and Steel
Bus Frame” Vol.2, Issue 12, December 2013.
[9] Amrendra Kumar Singh “Design and Analysis of chassis frame” IJRE.

[10] Patel Vijaykumar V “Structural Analysis of Automotive Chassis Frame and

Design Modification for Weight Reduction” IJERT

DEPARTMENT OF MECHANICAL ENGINERING 28