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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 10 Issue: 06 | Jun 2023

p-ISSN: 2395-0072

www.irjet.net

Design and impact analysis of an Automotive Frame Nishant Nanwani 1, Tanmay Kadam2, Karan Kataria3, Omkar Koratkar4 1Dhole Patil college of engineering, Kharadi, Pune 412207, India 2Dhole Patil college of engineering, Kharadi, Pune 412207, India 3Professor Bhushan Karamkar, Dept. of Automobile Engineering, Dhole Patil college of engineering, Pune, India

---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - The Automotive Frame has and always remains 1. INTRODUCTION the most essential component of any Vehicle and its main supporting backbone. Major components and systems of a vehicle are mounted on it such as the Engine, Powertrain i.e Gearbox, Differential, axles, and the suspension system which hugely depends on the vehicle frame and its strength, rigidity and durability. The frame is also required to provide protection in case of a collision and therefore should be accommodating in absorbing the impact's energy effectively without major deflections causing serious damage to the vehicle cabin and its passengers. A well-designed frame enhances the vehicle's overall performance, efficiency, and driving pleasure in addition to its structural integrity.

The Automotive Frame, also widely known as Chassis, is a vital structure of a vehicle that forms its backbone on which various systems and devices are mounted all together to make one complete unit. Additionally the frame is responsible for carrying the load of the passengers and systems while handling the sudden braking and acceleration forces and also the stresses involved due to many road irregularities. Between the period 1896-1910, vehicles used the traditional horse carriage as their support with members being made of wood and reinforced by wrought iron brackets. Shortly after the Ford model T was introduced with a ladder frame and became the popular choice of vehicle due to its robust build and lower cost due to mass manufacturing.

To help aid the above concerns, nowadays manufacturers use FEA softwares to analyse and simulate the event of an impact with varying parameters to see how well their frame design fairs and allows them to make necessary changes easily in the model and test again. This method reduces the testing costs greatly and allows researchers to find the perfect solution and optimal design to be further sent for building a successful prototype.

Alongside this advancements were made and new frame designs developed such as the Backbone chassis, X-frame, Platform frame, Perimeter Frame and finally the unibody in 1960 now widely known as monocoque frame.

In this study a ladder frame of a Toyota Tacoma 85’ has been designed with the help of Solidworks and further impact analysis has been carried out with the help of ANSYS software.

The ladder frame as the name suggests resembles the shape of a ladder with two long symmetrical beams or rails running on both sides consisting of cross members between to help support the vehicle cabin, systems and shell. Due to the floor pan sitting above the frame, the overall height of the vehicle was increased leading to a higher and undesirable CG (Centre of Gravity) compromising handling. Additionally this frame was also more stiff, heavy to use in sedans and hatchbacks and had poor resistance to torsion, causing manufacturers to use Backbone or Perimeter frames instead. Despite this the Ladder frame is still used widely in modern day SUVs, Pickup Trucks, busses and Trucks due to their strength, agility, flexibility , lower manufacturing costs and their simplicity, making them perfect for off roading usage.

With modern day advancements in the manufacturing and materials field, a number of valid and affordable materials can be chosen as an alternative to conventional use of aluminium and steel for a frame design such as composite materials and alloys. Carbon epoxy, Magnesium Alloy (AZ31B), Aluminium alloy, structural steel and Stainless steel have been considered to be used as frame material undergoing impact analysis and their results of maximum stress, strain and total deformation are compared along with their weight. Key Words: Impact analysis, Design, Ladder frame, FEA, Carbon epoxy, Magnesium alloy AZ31B, Aluminium alloy, Structural steel, Stainless steel.

Impact Factor value: 8.226

The 1904 Fiat 60 HP and the 1924 Bugatti Type 35 are two prominent early 20th-century vehicles that used backbone chassis. The design has been used by producers including Lotus, Ariel, and Ducati more recently. This chassis has a rectangular cross sectional tubular structure connecting both the front and rear axles with the shape of the human

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