LCV Chassis Frame Optimization Using Combined Simulation and Experimental Approach

The design and development of complete vehicle, understanding of chassis system development process is an important task. Chassis frame of a vehicle is supporting member, both structurally and functionally, to all other chassis aggregate systems viz. suspension, steering, braking system etc. In this paper, a methodology for chassis frame model construction and validation is explained. In present work, chassis frame model is validated in terms of modal parameters and also against static loading conditions. Existing chassis 3D Computer Aided Design (CAD) data was generated using scanning and cloud point data conversion technique. FE model was generated and validated through experimental measurements viz. modal testing, vertical bending, lateral bending, and torsional bending test. Loading and boundary conditions were replicated on the complete FE model in CAE domain and test validation was carried out using appropriate mesh biasing and weld modeling techniques. The chassis FE model was validated on the parameters of natural frequencies, mode shapes, and MAC correlation along with bending stiffness. The complete process gave an idea about the correlation environment between experimental and CAE domains. The correlated model was further used for Chassis optimization. The methodology proposed will not only gives a deep understanding and factors for real life correlation but also gives the insight of complete analysis procedure of ladder chassis frame.