Light Truck Frame Joint Stiffness Study Phase 1 Final Report

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JOINT STIFFNESS TOOLBOX Joint #1: Tube Through Tube Stiffness Calculations Input (mm) Test Design Window Design Variables (mm) Case 1 Case 2 Joint Min (mm) Max (mm) Thickness Crossmember 2.5 2.5 2.5 2 6 Side Rail 2.8 2.8 2.8 2 6 Shape Animations Shape Variables (mm) animations\JCrossmember Diameter 57 57 57 50 100 animations\JSide Rail Height 125 125 125 75 150 animations\JSide Rail Width 125 125 125 75 150 Output Loading Animations Stiffness Calculations Case 1 Case 2 Test Joint Units animations\JKx Bending Stiffness (Mx) 3.235 3.235 3.477 kN-m/deg animations\JKy Torsion Stiffness (My) 3.271 3.271 12.715 kN-m/deg animations\JKz Fore/Aft Stiffness (Mz) 3.507 3.507 3.662 kN-m/deg Mass 4.801 4.801 4.801 kg Yellow cells are user input data. Red cells are calculated numbers. Figure 32: Joint 1 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 59
JOINT STIFFNESS TOOLBOX Notes: * Modify the input values (yellow) based on your design criteria. There are two columns in which in to input and evaluate data, case 1 and case 2. The calculated stiffness will be displayed in red. * Design variables are listed in order of influence on stiffness. Illustration Key: A = Side Rail B = Crossmember Design Rules: * Make the crossmember diameter as large as possible. * Make the crossmember as thick as possible. * Thickness and diameter of the crossmember should be increased together if possible. * Click on the animation to the left of the variables and loading conditions to see an animation of respective shape variable or loading condition. * The mass calculation is based on 150 mm extension of joint members from the side rail to crossmember interface. (The crossmember is 150mm from the joint interface to the end of the crossmember). This caluclation is to serve as a reference, not the absolute value. * The password to unprotect cells in this spreadsheet is: steel. Joint Observations: * The crossmember is the most important part of this joint. The thickness of the crossmember is 3X more sensitive than the thickness of the side rail. * The maximum stress is in the crossmember at the connection to the inner side rail for all 3 Stiffness Cases. * The outer weld (the crossmember to outer side rail) could be a partial weld because this section of the joint has low stress. Figure 33: Joint 1 Joint Stiffness Toolbox Spreadsheet Joint Observations, Notes and Design Rules Report: A/SP-005-1 Light Truck Frame Joint Stiffness Study 60
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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 and 10: LITERATURE SEARCH Joint Stiffness T
Page 11 and 12: FINITE ELEMENT ANALYSIS Introductio
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: JOINT STIFFNESS TOOLBOX Introductio
Page 63 and 64: JOINT STIFFNESS TOOLBOX Notes: * Mo
Page 71 and 72: APPENDIX A: ABSTRACTS Read Articles
Page 73 and 74: APPENDIX A: ABSTRACTS 7. SCF Design
Page 75 and 76: APPENDIX A: ABSTRACTS 15. Deformati
Page 77 and 78: APPENDIX A: ABSTRACTS reasonable ag
Page 79 and 80: APPENDIX A: ABSTRACTS frequency err
Page 81 and 82: APPENDIX A: ABSTRACTS 36. Dynamic R
Page 83 and 84: APPENDIX A: ABSTRACTS 43. Behavior
Page 85 and 86: APPENDIX A: ABSTRACTS 6. Connection
Page 87 and 88: 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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