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SolidWorks_Ladder_Frame_Design_with_Material_Selection_Abhishek (1)

The document outlines the material selection and design process for a ladder frame chassis using Al 7075-T6 alloy, which is chosen for its high strength-to-weight ratio and low density. It details a step-by-step procedure for creating the chassis in SolidWorks, including sketching, mirroring, and assembling components. The material selection process emphasizes understanding requirements, identifying key properties, comparing materials, and validating choices through simulation tools like ANSYS.

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adv.adarshmaurya.highcourtlko
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16 views

SolidWorks_Ladder_Frame_Design_with_Material_Selection_Abhishek (1)

The document outlines the material selection and design process for a ladder frame chassis using Al 7075-T6 alloy, which is chosen for its high strength-to-weight ratio and low density. It details a step-by-step procedure for creating the chassis in SolidWorks, including sketching, mirroring, and assembling components. The material selection process emphasizes understanding requirements, identifying key properties, comparing materials, and validating choices through simulation tools like ANSYS.

Uploaded by

adv.adarshmaurya.highcourtlko
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Material Selection Process and

SolidWorks Design Process: Ladder


Frame Chassis
In our chassis project, we are need high load-bearing capacity but also want weight reduction.
Our analysis alloy is Al 7075-T6
This alloy offers low density. It also offers improved mechanical performance, making them
suitable for lightweight applications where strength and stiffness are important. It is low density
(around 1.82 g/cc).

Step-by-Step Procedure
Step 1: Start a New Part
Open SolidWorks → File → New → Part.

Step 2: Create the “C” Channel (Cross Section)


1. Select Front Plane → Click Sketch
2. Draw a C-section profile (7380mm×285mm with 7mm thickness)
3. Use Smart Dimension to fully define the sketch
4. Extrude to suitable 60 mm

Step 3: Mirror
Use Mirror along Right Plane (distance = 888 mm)

Step 4: Create Cross Members


1. Start Sketch on Top Plane
2. Draw a rectangle (Width: 888 mm)
3. Extrude to suitable height 60 mm
4. Use Linear Pattern to copy cross members at distances:
- 1185 mm (rear overhang), 1535 mm, 1411 mm, 1401.5 mm, 1141 mm, 707 mm (front
overhang)

Step 5: Assemble the Chassis (If in Assembly Mode)


1. Insert side rails and cross members as parts
2. Use Mate tool:
- Coincident Mate: Align faces
- Distance Mate: Control spacing
Export for Analysis

Save as .STEP or .IGES format for simulation in FEA tools like ANSYS.
Material Selection Process
Material selection is a critical part of the design process. The chosen material impacts
strength, weight, durability, cost, and performance. The following steps describe the
material selection process for the ladder frame chassis.

Step 1: Understand the Requirements


Define what the material must endure (e.g., load, weight, environment). For a truck chassis:
high strength, good fatigue resistance, moderate cost, and reduced weight are desired.

Step 2: Identify Key Properties


Key properties include:
- Yield strength and tensile strength
- Density (for lightweight design)
- Fatigue resistance
- Cost and availability
- Corrosion resistance

Step 3: Shortlist Candidate Materials


Examples for automotive applications include:
- Alloy Steel ASTM A710
- Aluminium Alloy 7075-T6

Step 4: Compare Materials


Use material databases or Ashby charts to compare properties. For instance:
- ASTM A710: High strength and durability
- Al 7075-T6: Lightweight with good strength-to-weight ratio

Step 5: Evaluate Trade-offs


Balance factors like cost vs. performance. Example: Aluminum reduces weight but may have
higher cost.

Step 6: Final Selection


Choose the material that offers the best performance for your specific application. In this
project, both ASTM A710 and Al 7075-T6 were analyzed for comparison.

Step 7: Validate with Simulation


Perform static, modal, fatigue, and buckling analysis in ANSYS or SolidWorks Simulation to
confirm material suitability under real-world conditions.

Prepared by: Abhishek Gupta


Date: April 29, 2025

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