moonbuggy rear suspension analysis me450: computer-aided engineering analysis
DESCRIPTION
Moonbuggy Rear Suspension Analysis ME450: Computer-Aided Engineering Analysis Department of Mechanical Engineering, IUPUI Instructor: Dr. Koshrow Nematollahi May 1, 2006 John Fearncombe Brandin Ray Amber Russell. Objectives. - PowerPoint PPT PresentationTRANSCRIPT
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Moonbuggy Rear Suspension Analysis
ME450: Computer-Aided Engineering Analysis
Department of Mechanical Engineering, IUPUI
Instructor: Dr. Koshrow NematollahiMay 1, 2006
John FearncombeBrandin RayAmber Russell
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Objectives
• Perform finite element analysis of moon buggy suspension using ANSYS Workbench
• Evaluate stress and deformation resulting from applied load
• Perform iterations as needed until a satisfactory design is realized
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Introduction
• Moon buggy originally designed in Spring 2005 by ME 462 design team
• Lower a-arms on original suspension failed
• Normal loading conditions were determined to be approximately 200 pounds-force
• The initial design was modeled to determine if it could be modified and safely used
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Theoretical Background
•Utilized ten-node SOLID92 tetrahedral elements•Ideal for complicated solids with curved boundaries
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Model Details for Existing Design
• Originally modeled in Pro/Engineer (IGES), then imported into ANSYS Workbench
• Static analysis only• Aluminum alloy construction• 200 pounds-force load applied at
shock mount• Fixed supports at axes of rotation• Displacement constrained in
transverse direction
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ANSYS Workbench Model of Existing Design
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Deformed Geometry for Existing Design
•Maximum Deflection of 2.78×10-3 inches•Maximum deformation occurs near shock absorber mount
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Principal Stresses for Existing Design
•Maximum principal stress of 1.791 ksi•Yield stress for 6061 aluminum alloy is 35 ksi•Maximum stresses occur where the part failed
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Shear Stress for Existing Design
•Maximum shear stress of 1.421 ksi•Deemed insignificant•Failure due to fatigue in aluminum
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Model Details for First Iteration
• Modeled and constrained as before• Aluminum alloy construction• 200 pound-force load again applied
at shock mount• Modeled as one-piece construction
with no welds
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Results - ANSYS Model of First Iteration
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Deformed Geometry for First Iteration
•Maximum Deflection of 5.42×10-3 inches•Occurs below shock absorber mounting bolt
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Principal Stresses for First Iteration
•Maximum principal stress of 221.267 psi•Yield stress for 6061 aluminum alloy is 35 ksi•Maximum stresses occur near the shock absorber mounting bolt
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Shear Stress for First Iteration
•Maximum shear stress of 20.917 psi•Shear stress concentrated near welds•Quality of welds had been an issue
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Model Details for Final Iteration
• Modeled and constrained as before• Aluminum alloy construction with
steel reinforcement plates at shock absorber mount
• Two points of attachment to wheel hub housing to relieve stress on aluminum members
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ANSYS Workbench Model of Final Iteration
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Deformed Geometry for Final Iteration
•Maximum Deflection of .114×10-3 inches•Located at mid-section of shock absorber bolt
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Principal Stresses for Final Iteration
•Maximum principal stress of 1.875 ksi•Yield stress:
–6061 aluminum alloy is 35 ksi–4140 steel is 45 ksi
•Maximum stresses occur in the steel reinforcing plates
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Shear Stress for Final Iteration
•Maximum shear stress of 1.170 ksi•Located in steel reinforcing plates•Achieved objective of localizing stresses within steel elements
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Impact Statement
• Through the use of finite element analysis on the rear suspension of the moon buggy the vehicle has become more safe, stable, and easier to maintain.
• By optimizing the design before production, we have alleviated costly and potentially dangerous failures.
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Conclusion - Advantages of Final Iteration
• Maximum stress is distributed on steel reinforcing plates
• Ability to quickly and inexpensively replace the parts most likely to fail
• Easier fabrication• No reliance on welds for structural
stability
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Suspension Test
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Bibliography
• ME 450 Course Text• ANSYS Website www.ansys.com• Car Suspension and Handling. Bastow,
Donald. London : Pentech Press ; Warrendale, Penn. : Society of Automotive Engineers, 1993.
• Chassis design : principles and analysis Milliken, William F., 1911-
• www.engineersedge.com – Material Properties