Frame Design of a Passenger Vehicle of M3 Category Using Design of Experiments 2019-26-0318
The chassis frame of the passenger vehicle is one of the primary load bearing components of the vehicle. All the aggregates such as engine, radiator, fuel tank, urea tank, air tanks, body and cowl etc are mounted on to the frame. It should have sufficient stiffness and strength to withstand the static and dynamic loads. At the same time it should also be light in weight as it helps in reducing the fuel consumption and emissions coming out of the vehicle. The main objective of this work is to learn the methodology of designing a chassis frame of a passenger vehicle of M3 category by considering the stiffness and the natural frequency of a similar type of vehicle (Benchmark) as the target values i.e. the final design of the frame should match the stiffness and natural frequency values of the benchmarked frame with a specified tolerance set by the design team. Apart from these, the frame is also optimized to attain a minimum weight by adding/ removing reinforcements etc in order to keep the weight of the frame to a minimum value, without compromising on its stiffness and natural frequency values that are to be matched with the values of legacy frame in all the loading cases. As weight optimization of chassis frame is a tedious iterative process, we use Central Composite Design technique in Design of Experiments to find out the optimized cross section for long member such that the frame assembly can match the stiffness and natural frequency values with that of the legacy frame’s values in all loading cases, thereby avoiding the unwanted iterations.