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Frame Structure Durability Development Methodology for Various Design Phases
ISSN: 0148-7191, e-ISSN: 2688-3627
Published April 14, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
It is a challenging task to find an optimal design concept for a truck frame structure given the complexity of loading conditions, vehicle configurations, packaging and other requirements. In addition, there is a great emphasis on light weight frame design to meet stringent emission standards. This paper provides a framework for fast and efficient development of a frame structure through various design phases, keeping durability in perspective while utilizing various weight reduction techniques. In this approach frame weight and stiffness are optimized to meet strength and durability performance requirements.
Fast evaluation of different frame configurations during the concept phase (I) was made possible by using DFSS (Design for Six Sigma) based system synthesis techniques. This resulted in a very efficient frame ladder concept selection process. Frame gauge optimization during the subsequent development phase (II) utilizing a newly developed damage based approach greatly reduced the number of design iterations relative to a typical stress based approach. In the light weighting phase (III) that followed, a method was established to effectively locate and optimize lightening holes using fatigue damage contours. In the final optimization phase (IV) custom Python® scripts were developed to optimize weld lengths at joints.
This whole framework provides a fast and efficient way to optimize a frame structure for durability.
CitationThandhayuthapani, C., Lin, B., Mao, J., Byali, R. et al., "Frame Structure Durability Development Methodology for Various Design Phases," SAE Technical Paper 2020-01-0196, 2020, https://doi.org/10.4271/2020-01-0196.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
- Zhang, S. and Chen, A. , “A Practical Design Process to Optimize Fatigue Performance for Chassis Components,” SAE Technical Paper 2009-01-1227 , 2009, https://doi.org/10.4271/2009-01-1227.
- Sohmshetty, R. and Mallela, K. , “Advanced High Strength Steels for Chassis Structures,” SAE Technical Paper 2008-01-0854 , 2008, https://doi.org/10.4271/2008-01-0854.
- Sithik, M., Vallurupalli, R., Lin, B., and Sudalaimuthu, S. , “Simplified Approach of Chassis Frame Optimization for Durability Performance,” SAE Technical Paper 2014-01-0399 , 2014, https://doi.org/10.4271/2014-01-0399.
- Chen, G., Guo, M., and Zhang, W. , “Fatigue Based Lightweight Optimization of a Pickup Cargo Box with Advanced High Strength Steels,” SAE Int. J. Mater. Manf. 7(3):545-552, 2014, http://dx.doi.org/10.4271/2014-01-0913.
- “Altair OptiStruct™ with Linear Stress Analysis and Gauge Optimization by Altair Hyperworks™.”
- Lin, B., Bhat, R., Zhang, S., and Sykes-Green, T. , “A New Weight Reduction Lightening Holes Development Approach Based on Frame Durability Fatigue Performance,” SAE Technical Paper 2017-01-1348 , 2017, https://doi.org/10.4271/2017-01-1348.
- Bhat, R., Sharma, N., Rivard, C., and Thomson, K. , “Simplified Approach for Optimizing Lightening Holes in Truck Frames for Durability Performance,” SAE Technical Paper 2017-01-1345 , 2017, https://doi.org/10.4271/2017-01-1345.
- “DesignLife® Theory Guide and nCode® 2019 Fatigue Solver by HBM Prenscia.”