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ME450: Computer-Aided Engineering Analysis Department of Mechanical Engineering, IUPUI Instructor: Dr. Koshrow Nematollahi
May 1, 2006
Objectives
Perform finite element analysis of moon buggy suspension using ANSYS Workbench Evaluate stress and deformation resulting from applied load Perform iterations as needed until a satisfactory design is realized
Introduction
Moon buggy originally designed in Spring 2005 by ME 462 design team Lower a-arms on original suspension failed Normal loading conditions were determined to be approximately 200 pounds-force The initial design was modeled to determine if it could be modified and safely used
Theoretical Background
Utilized ten-node SOLID92 tetrahedral elements Ideal for complicated solids with curved boundaries
Maximum principal stress of 1.791 ksi Yield stress for 6061 aluminum alloy is 35 ksi Maximum stresses occur where the part failed
Maximum shear stress of 1.421 ksi Deemed insignificant Failure due to fatigue in aluminum
Maximum Deflection of 5.4210-3 inches Occurs below shock absorber mounting bolt
Maximum principal stress of 221.267 psi Yield stress for 6061 aluminum alloy is 35 ksi Maximum stresses occur near the shock absorber mounting bolt
Maximum shear stress of 20.917 psi Shear stress concentrated near welds Quality of welds had been an issue
Maximum shear stress of 1.170 ksi Located in steel reinforcing plates Achieved objective of localizing stresses within steel elements
Impact Statement
Through the use of finite element analysis on the rear suspension of the moon buggy the vehicle has become more safe, stable, and easier to maintain. By optimizing the design before production, we have alleviated costly and potentially dangerous failures.
Suspension Test
Bibliography
ME 450 Course Text ANSYS Website www.ansys.com Car Suspension and Handling. Bastow, Donald. London : Pentech Press ; Warrendale, Penn. : Society of Automotive Engineers, 1993. Chassis design : principles and analysis Milliken, William F., 1911 www.engineersedge.com Material Properties