Light Truck Frame Joint Stiffness Study Phase 1 Final Report

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LITERATURE SEARCH Measurements: • To evaluate the initial stiffness of the connection, the following assumptions are made: the material is linear elastic, the deformations are small and mainly due to bending and in-plane deformations are negligible (Korol et al., 1996) • Measurement should be set up allowing for both the rotations of the connections as a whole and the contributions of the various components to be obtained (Bernuzzi et al., 1996) FE Model: • All nodes lying on the cut surfaces of the model should be subjected to an imposed boundary condition in which displacements normal to the plane of symmetry and rotations about that plane are restrained (Chiew et al., 1996) • For closer correlation with experimental measurements, it is necessary to model the variation of thickness in the cross-section of the rail and crossmember and the corner radii as realistically as possible (Van Wingerde, 1992) Conclusions Valuable information in testing, FEA joint stiffness and sensitivity studies provided a basis of information to initiate the light truck frame joint stiffness study and the development of guidelines for improving joint stiffness. Ultimately, the literature search revealed that no current studies are available in open publications specifically evaluating truck frame joint stiffness and parameterizing those values that affect joint stiffness. Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 9
FINITE ELEMENT ANALYSIS Introduction Finite element analysis was used to evaluate the stiffness of five different light truck frame joints. Using information from the literature search and fundamental finite element techniques, the joints were postprocessed to understand model and joint behavior, and to compare FEA results to physical test data. The study included defining the joint, modeling, determining the loading conditions and evaluating the stiffness of the joints. A picture of each joint and a brief description are shown in Figures 1 through 5. Figure 1: Joint 1: Tube-Through-Tube (welded to both webs) Figure 2: Joint 2: Box to Lipped Channel Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 10
Page 1 and 2: Light Truck Frame Joint Stiffness S
Page 3 and 4: EXECUTIVE SUMMARY Background There
Page 5 and 6: TABLE OF CONTENTS Introduction ....
Page 7 and 8: LITERATURE SEARCH Introduction A li
Page 9: LITERATURE SEARCH Joint Stiffness T
Page 13 and 14: FINITE ELEMENT ANALYSIS Defining th
Page 15 and 16: FINITE ELEMENT ANALYSIS Load Applie
Page 17 and 18: FINITE ELEMENT ANALYSIS z L: Load F
Page 19 and 20: FINITE ELEMENT ANALYSIS Table 1: An
Page 21 and 22: TESTING PROCEDURE Test Repeatabilit
Page 23 and 24: TESTING PROCEDURE Joints 1 - 4 Pneu
Page 25 and 26: TESTING PROCEDURE Joint 1 - X Direc
Page 27 and 28: TESTING PROCEDURE Joint 1 - Torsion
Page 41 and 42: TESTING PROCEDURE Joint 5 - Hanging
Page 43 and 44: TESTING PROCEDURE Joint 5 - Z Direc
Page 45 and 46: TESTING PROCEDURE Joint Stiffness S
Page 47 and 48: TESTING PROCEDURE Table 2: Test Joi
Page 49 and 50: CORRELATION Table 3: Test and Analy
Page 51 and 52: SENSITIVITY STUDY The influence of
Page 53 and 54: SENSITIVITY STUDY C- Channel Gage C
Page 55 and 56: SENSITIVITY STUDY C- Channel Gage C
Page 57 and 58: SENSITIVITY STUDY Crossmember Gage
Page 59 and 60: JOINT STIFFNESS TOOLBOX Introductio
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JOINT STIFFNESS TOOLBOX Notes: * Mo
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APPENDIX A: ABSTRACTS Read Articles
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APPENDIX A: ABSTRACTS 7. SCF Design
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APPENDIX A: ABSTRACTS 15. Deformati
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APPENDIX A: ABSTRACTS reasonable ag
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APPENDIX A: ABSTRACTS frequency err
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APPENDIX A: ABSTRACTS 36. Dynamic R
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APPENDIX A: ABSTRACTS 43. Behavior
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APPENDIX A: ABSTRACTS 6. Connection
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APPENDIX B: MATERIAL TESTING REPORT
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APPENDIX C: TEST RESULTS Joint 1 Fo
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APPENDIX C: TEST RESULTS Joint 2 Ve
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APPENDIX C: TEST RESULTS Joint 3 To
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APPENDIX C: TEST RESULTS Joint 5 Fo
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APPENDIX D: DIAGRAM OF JOINT IN TES
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Light Truck Frame Joint Stiffness Study Phase 1 Final Report

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