The topic for this master’s Diploma thesis is “Analysis and subsequent optimization of the support frame for the 1: 1 design model”. The central aim of this thesis work is to analysis the frame design with given parameters and design a new frame with all requirements in terms of weight reduction, stiffness and price.
The thesis work has five parts:Ø FEM Analysis of existing frame Ø Selection of new material for the frameØ Proposal for new model frameØ FEM analysis of new model frameØ Results and comparisons of both framesThe initial few chapters of the thesis work describe the theoretical part of the work, composed of the literature study and research from sources. It contains about chassis design and materials for conventional frames. There are very fewer sources especially about clay modelling frame design but it has similarities with real car chassis design for that we have a lot of sources.so initially studied the chassis design and it very helpful for new frame design. The core plot of the project is Finite element analysis.Initially, a detailed study was done about existing frame design, dimensions and its parameters.
Using the dimensions, a 3-D CAD model frame was created using CATIA V5-6 and then the 3-D model converted to step file. Finally, Finite element analysis is performed by using ANSYS17.1.Using SWOT analysis, the new model was designed very carefully to meet all required parameters. For modelling and analysis, the same procedure followed like the former.
Finally, the results of both frames compared.The most important part of the analysis is taking boundary conditions, loading conditions. If there is any mistake in boundary, loading conditions it may give wrong results during analysis. In our case, there is no dynamic load only static load due to clay and foam. The major load is clay. In boundary conditions, there are four fixed positions and for loading conditions, there are two possibilities .one is design the clay, foam and placed upon frame the other one is calculating the force and apply it directly on contacted area in frame.