Modal analysis of automotive chassis using ANSYS software and to compare the observation with experimental results on chassis

using shaker and impact testing

SHANIA BAIG MALIK M SHAMSHAD AMJAD ALI ABRO KASHIF ALI

AU-045 AU-016 AU-302 AU-020

ENGR. UMAIR NAJEEB MUGHAL (ASST. PROFESSOR)

To design the automotive chassis in a cad software (UG) To apply modal analysis on cad model of chassis using ANSYS To observe the frequency and mode shape of three initial modes To apply impact testing on chassis to obtain frequency response function

Compare computational and experimental results and study the variation

LEARNING PHASE o Study Fundamentals of Vibration and Modal Analysis oGetting acquainted with ANSYS oExperimental Modal Analysis on beams oLearning Fast Fourier Transforms oSeek for Dimension of chassis PRACTICAL PHASE o Designing of chassis in CAD (Unigraphics) o Apply Modal Analysis on chassis using ANSYS and interpret results o Measurement of Frequency Response Function (FRF) using Impact testing and extraction of first three natural frequency and mode shapes FINAL PHASE

o Comparison of results obtained from experimentation and

simulation

Modal analysis studies the dynamic properties or structural characteristics of a mechanical structure under dynamic excitation oResonant frequency oMode shapes oDamping

Noise Vibration and Harshness (NVH) Response of ground vehicles

It is very important in the aircraft structures and gas turbine engines for finding the optimum operating range
Nowadays it has become an important part of civil engineering for design of structures in the earthquake areas

In the well-known case of the Tacoma bridge, the damping was not high enough to absorb all the excitation energy.

When spinning, the washing machines drum vibrations induce such a powerful resonant frequency that the machine begins to actually move causing the door to spring open.

Any motion that repeats itself after an interval of time is called vibration or oscillation.

Vibration is used to describe oscillatory motion of mechanical and structural systems.

The vibration of a system involves the transfer of its potential energy to kinetic energy and kinetic energy to potential energy, alternately.

The minimum number of independent coordinates required to determine completely the positions of all parts of a system at any instant of time

Arrangement of components to interchange kinetic energy to Potential energy and Potential energy to Kinetic energy to form an oscillatory motion

Mass (stores Kinetic energy) Spring (stores Potential energy) Damper (Dissipates energy gradually)

A system having finite degrees of freedom is known as discrete or lumped parameter system

A system having infinite degrees of freedom is know as continuous system or distributed system

When system is left to vibrate freely after initial disturbance

The study of motion as a result of loads that vary with time

No energy is lost in friction or other resistance during oscillation

some energy is lost in friction or other resistance during oscillation

If the magnitude of excitation at any instant time can be found this type of vibration is called Deterministic Vibration. Example is a harmonic excitation i.e. sine wave

If the magnitude of excitation can not be easily known at any instant of time this type of vibration is called Random Vibration. Example is road excitation

Such vibration in which all parts of vibratory system behave Linearly is called Linear vibration

If any of the part of Vibratory system behaves nonlinearly this is called nonlinear vibration

The movement of vibratory system to cover 2 radians of angular displacement

Number of cycles completed in one second is known as frequency

Time taken to complete one cycle of vibration is known as time period of oscillation

The maximum displacement of vibratory system from its mean position is known as amplitude

IT DESCRIBES THE POSITION OF THE WAVEFORM RELATIVE TO TIME ZERO.

Any periodic function can be expressed as the sum of a series of sines and cosines (of varying amplitudes), e.g. Square waves, saw tooth wave and others.

Fourier series can be generalized to complex numbers, and further generalized to derive the Fourier transform.

Fourier transform maps a time series into the series of frequencies that composed the time series. Inverse Fourier transform maps the series of frequencies back into the corresponding time series.

The frequency - amplitude axes define the frequency plane in a manner similar to the way the time plane is defined by the time -amplitude axes. The frequency plane is orthogonal to The time plane, and intersects with it On a line which is the amplitude axis The projection of the sinusoid onto the frequency plane is simply a line equal to the amplitude of the sinusoid.

According to Fourier analysis, any composite signal can be represented as a combination of simple sine waves with different frequencies, phases, and amplitudes.

Modal analysis studies the dynamic properties or structural characteristics of a mechanical structure under dynamic excitation:
oResonant frequency oMode shapes oDamping

It refers to a complete process including both an acquisition phase and an analysis phase. The structure is excited by external forces such as an impact hammer or shaker.

Modal testing systems consist of transducers (typically accelerometers and force cells), an analog to digital converter or front-end to digitize the analog instrumentation signals and a host pc to review and analyze the data
When the output is fixed and FRFs are measured for multiple inputs, this corresponds to measuring elements from a single row of the FRF matrix. This is typical of a roving hammer impact test.

When the input is fixed and FRFs are measured for multiple outputs, this corresponds to measuring elements from a single column of the FRF matrix. This is typical of a shaker test.

Apply a force that varies in a sinusoidal fashion on one corner.

Change the rate of oscillation (frequency rate) of the sinusoidal force, but the peak force stays the same Measure the response of the excitation with an accelerometer attached to the other corner of the plate. The measured amplitude can vary depending on the frequency rate of the input force. The response amplifies as we apply a force with a frequency rate that gets closer and closer to the systems resonant or natural frequencies. The resonant frequency is the frequency at which any excitation produces an exaggerated response.

Modes (or resonances) are inherent properties of a structure. Resonances are determined by the material properties (mass, stiffness, and damping properties), and boundary conditions of the structure. Each mode is defined by a natural (modal or resonant) frequency.

All structures can have up to six rigid body modes, three translational modes and three rotational modes

The FRF describes the input-output relationship between two points on a structure as a function of frequency An FRF is a measure of how much displacement, velocity, or acceleration response a structure has at an output DOF, per unit of excitation force at an input DOF The ratio of the Fourier transform of an output response divided by the Fourier transform of the input force that caused the output

Structural dynamics measurement involves measuring elements of an FRF matrix model for the structure FRF matrix columns correspond to inputs, and rows correspond to outputs. Each input and output corresponds to a measurement DOF of the test structure.

1.

An IMPACT HAMMER with a load cell attached to its head to measure the input force.

2. An ACCELEROMETER to measure the response acceleration at a fixed point & direction. 3. A 2 or 4 channel FFT ANALYZER to compute FRFs. 4. Post-processing MODAL SOFTWARE for identifying modal parameters and displaying the mode shapes in animation.

Impact testing is a fast, convenient, and low cost way of finding the modes of machines and structures.

When impact testing cannot be used, FRF measurements must be made by providing artificial excitation with one or more shakers, attached to the structure.
Common types of shakers are electro-dynamic and hydraulic shakers. A shaker is usually attached to the structure using a stinger (long slender rod), so that the shaker will only impart force to the structure along the axis of the stinger A load cell is then attached between the structure and the stinger to measure the excitation force. At least a 2-channel FFT analyzer and accelerometer are required to make FFT measurements using a shaker.

1st lateral bending

2nd lateral bending

1st tensional

2nd tensional

1st vertical bending

2nd vertical bending

Material: mild steel Length: 1025mm Width: 64mm Thickness: 1.4mm Youngs Modulus: 167Gpa Poison ratio:0 Density of mild steel: 7.1E-6 kg/mm3 Moment of inertia: 14.634 in4 Area:89.6 in2

No. of modes applied: 2 Amplitude: 2mm Frequency of 1st mode: 5.35 Hz Frequency for 2nd mode: 36.8 Hz

ELEMENTS

MAY

21 2010 13:36:45

Y Z X

***** INDEX OF DATA SETS ON RESULTS FILE *****

SET TIME/FREQ LOAD STEP SUBSTEP 1 5.8932 1 1 1 2 36.932 1 2 2

DISPLACEMENT STEP=1 SUB =1 FREQ=5.893 DMX =2.477

MAY 21 2010 13:22:05

Y Z X

1st MODE SHAPE OF BEAM FREQUENCY: 5.893 DISPLACEMENT MAX: 2.477mm

DISPLACEMENT STEP=1 SUB =2 FREQ=36.932 DMX =2.477

MAY 21 2010 13:21:41

Y Z X

2nd MODE SHAPE OF BEAM FREQUENCY: 36.932 DISPLACEMENT MAX: 2.477mm

SIMULATION

EXPERIMENATL

AMPLITUDE

5.893

5.35

FREQUENCY

36.932

36.8

Visited Metal Engineering Works Limited for taking dimensions of truck chassis Taken the measurements FL-1J and modeled it in Unigraphics But the dimensions taken were not accurate as they were taken from a fully assembled truck Visited Hinopak limited for dimension and approval for on three time but they disapproved to use their drawings, and will not allow testing on chassis

Proper dimensions of chassis are not available for accurate simulation

Structure for Modal testing is not available

The fully assembled truck structure is available which cannot be used, because it is mounted on the suspension if apply modal analysis it will give response of the structure, we need to constraint the structure from four places we therefore request for arrangement of structure for testing purpose

To apply modal analysis on truck chassis using ANSYS and observe frequency of specified modes

To apply experimental analysis on truck chassis using impact testing and obtain the frequency of specified modes
Compare and study both the results, and conclude with opinion.