LIGHT COMMERCIAL VEHICLES – Project topics materials

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INTRODUCTION

The engineering discipline of structural mechanics comprises specialist fields such as structural dynamics, strength of materials, finite element methods, fatigue, durability testing and fracture mechanics. In basic terms, each of these subjects is based on mathematical models used to simulate the behaviour of structures in terms of outputs such as deflections, stresses, vibration and various failure mechanisms.

Problem Definition

Tank containers transport bulk products (mostly liquid and often dangerous) by ship, rail and truck. The container structures are subjected to exceptionally harsh dynamical loading conditions such as impact loading in train shunting yards, abusive handling by cranes and forklifts in depot yards, dynamic loading in storms when stacked 8 high in ship holds and fatigue loads induced by rough roads.

Methodology

The durability assessment comprised the following steps:
• Finite element assisted design according to available design code prescribed loads.
• Building of prototype vehicle.
• Strain gauge measurements on prototype vehicle for typical operational cycles.
• Establishment of design criteria for fatigue loading.
• Redesign and extensive fatigue assessment using finite element and measurement results.

SCOPE

In this chapter, the fundamental theory underpinning the techniques covered in the present study, as well as methodologies with regard to the determination of input loading, structural fatigue design and testing of vehicular structures, are presented. The chapter firstly deals with the various analysis and testing methods, involved in vehicle structural design and assessment and then discusses the techniques used to determine inputs for these methods.

1. INTRODUCTION
2. DEFINITION OF CASE STUDIES
2.1 SCOPE
2.2 LIGHT COMMERCIAL VEHICLES
2.2.1 Minibus
2.2.2 Pick-up Truck
2.2.3 Problem definition
2.3 FUEL TANKER
2.3.1 Problem definition
2.3.2 Methodology
2.4 ISO TANK CONTAINER
2.4.1 Problem Definition
2.4.2 Methodology
2.5 INDUSTRIAL VEHICLES
2.5.1 Load Haul Dumper
2.5.2 Ladle Transport Vehicle
2.6 CLOSURE
3. FUNDAMENTAL THEORY AND METHODOLOGIES
3.1 SCOPE
3.2 FINITE ELEMENT ANALYSIS
3.2.1 General
3.2.2 Static Load Analysis
3.2.3 Dynamic Analysis
3.2.4 Summary
3.3 MULTI-BODY DYNAMIC SIMULATION
3.4 DURABILITY ASSESSMENT
3.4.1 General
3.4.2 Fatigue Analysis
3.4.3 Cycle Counting
3.4.4 Damage Accumulation
3.4.5 Frequency Domain Fatigue Life
3.4.6 Durability Testing
3.4.7 Statistical Analysis
3.5 DETERMINATION OF INPUT LOADING
3.5.1 General
3.5.2 Sources and Classification of Loading
3.5.3 Design Load Spectrum
3.5.4 Test Load Spectrum
3.5.5 Road Roughness as a Source of Vehicle Input Loading
3.5.6 Vibration
3.5.7 Limit State and Operational State
3.5.8 Design and Testing Criteria
3.6 CLOSURE
4. MEASUREMENTS, SURVEYS AND SIMULATION
4.1 SCOPE
4.2 MEASUREMENTS
4.2.1 General
4.2.2 Methodology
4.2.3 Minibus
4.2.4 Pick-up Truck
4.2.5 Fuel Tanker
4.2.6 ISO Tank Container
4.2.7 Load Haul Dumper
4.2.8 Ladle Transport Vehicle
4.3 SURVEYS
4.3.1 General
4.3.2 Methodology
4.3.3 Minibus
4.3.4 Pick-up Truck
4.4 SIMULATION
4.4.1 General
4.4.2 ISO Tank Container
4.5 CLOSURE
5. DESIGN AND TESTING REQUIREMENTS
5.1 SCOPE
5.2 FUNDAMENTAL INPUT LOADING
5.2.1 General
5.2.2 Maximum Loading Limit State
5.2.3 Dynamic Finite Element Analysis
5.3 HYBRID MODAL SUPERPOSITION / REMOTE PARAMETER METHOD
5.3.1 General
5.3.2 Ladle Transport Vehicle
5.4 FATIGUE EQUIVALENT STATIC LOADING
5.4.1 General
5.4.2 Methodology
5.4.3 Comparison with Remote Parameter Analysis Method
5.4.4 Fuel Tanker
5.4.5 ISO Tank Container
5.4.6 Load Haul Dumper
5.5 STATISTICAL MODEL
5.5.1 General
5.5.2 Methodology
5.5.3 Minibus
5.5.4 Pick-up Truck
5.6 TESTING REQUIREMENTS
5.6.1 General
5.6.2 Minibus
5.6.3 Pick-up Truck
5.6.4 ISO Tank Container
5.7 CLOSURE
6. FATIGUE ASSESSMENT AND CORRELATION
6.1 SCOPE
6.2 FATIGUE LIFE PREDICTION
6.2.1 General
6.2.2 Minibus
6.2.3 Pick-up Truck
6.2.4 Fuel Tanker
6.2.5 Ladle Transport Vehicle
6.2.6 Load Haul Dumper
6.3 DESIGN CODE CORRELATION
6.3.1 General
6.3.2 Fuel Tanker
6.4 DERIVATION OF USAGE PROFILE FROM FIELD FAILURE DATA
6.4.1 General
6.4.2 Methodology
7. FORMALISATION
7.1 SCOPE
7.2 GENERALISED UNIFIED METHODOLOGY
7.2.1 General
7.2.2 Commencement of Input Loading Establishment (Red Decision Block)
7.2.3 Measurement Profile
7.2.4 Data Format
7.2.5 Simulation
7.2.6 Survey
7.2.7 Field Failures
7.2.8 Ellipse Fitting
7.2.9 Sales Data
7.2.10 Fatigue Processing
7.2.11 Remote Parameter Analysis
7.2.12 Fatigue Equivalent Static Loading
7.2.13 Fatigue Test
7.2.14 Finite Element Analysis
7.2.15 Usage Profile
7.2.16 Monte Carlo
7.2.17 Probabilistic Analysis
7.2.18 Failure Prediction
7.2.19 Test Requirements
7.2.20 Fatigue Design Loads
7.2.21 Maximum Loads
7.3 CASE STUDIES ACCORDING TO GENERALISED PROCESS
7.3.1 Minibus
7.3.2 Pick-up Truck
7.3.3 Fuel Tanker
7.3.4 ISO Tank Container
7.3.5 Ladle Transport Vehicle
7.3.6 Load Haul Dumper
8. CONCLUSION
9. REFERENCES