Finite Element Analysis of a vehicle chassis cross - member spot weld design

Abstract

This paper addresses the analysis of LDV light commercial van chassis cross member spot weld design. First the experimental test was conducted to measure the deflection and strain values under different load conditions. A linear elastic finite element analysis was done on the beam to obtain predictions of deflections and strains at strain gauge locations and compare with measured values and the finite element predictions was analysed through the manual calculations based on Mechanics of Materials. The structure was modelled with two main solid parts and spot welded together and the spot welds were modelled by using point icon through Ansys 14 software. The main part and model generated by using Solidworks software during the study. The results were compared and validated to develop a suitable FEA model for design change analysis. Finally an efficient and cost effective design was proposed.