Light Truck Frame Joint Stiffness Study Phase 1 Final Report

TABLE OF CONTENTS
Introduction ......................................................................................................................................... 5
Literature Search................................................................................................................................. 6
Introduction ............................................................................................................................ 6
Defining the Joint ................................................................................................................... 6
Testing ................................................................................................................................... 7
Finite Element Analysis.......................................................................................................... 7
Joint Stiffness......................................................................................................................... 8
Lessons Learned.................................................................................................................... 8
Conclusions............................................................................................................................ 9
Finite Element Analysis..................................................................................................................... 10
Introduction .......................................................................................................................... 10
Defining the Joints................................................................................................................ 12
Finite Element Analysis Model............................................................................................. 13
Loading Conditions ..............................................................................................................14
Stiffness Calculations........................................................................................................... 15
Table 1: Analysis Stiffness Summary .................................................................................. 18
Testing Procedure............................................................................................................................. 19
Introduction .......................................................................................................................... 19
Joint Preparation .................................................................................................................. 19
Joint Fixturing....................................................................................................................... 19
Deflection Measurement ...................................................................................................... 19
Force Application ................................................................................................................. 19
Test Repeatability ................................................................................................................ 20
Joints 1-4 Joint Preparation and Fixturing ........................................................................... 21
Joints 1-4 Pneumatic Cylinder Setup................................................................................... 22
Joint 1 Joint Sample and Test Setup ................................................................................... 23
Joint 2 Joint Sample and Test Setup ................................................................................... 27
Joint 3 Joint Sample and Test Setup ................................................................................... 31
Joint 4 Joint Sample and Test Setup ................................................................................... 35
Joint 5 Joint Preparation and Fixturing ................................................................................ 39
Joint 5 Hanging Weight Setup ............................................................................................. 40
Joint 5 Joint Sample and Test Setup ................................................................................... 41
Joint Stiffness Summary ...................................................................................................... 44
Data...................................................................................................................................... 44
Table 2: Test Joint Stiffness Summary ................................................................................ 46
Correlation......................................................................................................................................... 47
Introduction .......................................................................................................................... 47
Correlating the Test and Analysis Data ............................................................................... 47
Table 3: Test and Analysis Joint Stiffness Correlation Summary........................................ 48
Sensitivity Study................................................................................................................................49
Introduction .......................................................................................................................... 49
Joint Parameters .................................................................................................................. 49
Joint Stiffness Toolbox...................................................................................................................... 58
Introduction .......................................................................................................................... 58
References........................................................................................................................................ 69
Appendix A: Abstracts....................................................................................................................... 70
Appendix B: Material Testing Report ................................................................................................ 86
Appendix C: Test Results................................................................................................................ 110
Appendix D: Diagram of Joint in Test Fixture ................................................................................. 118
Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 4