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Vibration Analysis of Tractor fender Assembly and Test

Correlation Using Optistruct

Eicher Tractors, Mandideep

Pawan Singh
Manager, CAE

Javed Quershi
Junior Manager, CAE

Rohit Lilhare
Junior Manager, CAE

Date: 13/06/2014
Company Profile

TAFE Motors and Tractors Limited ( TMTL ) is a wholly owned subsidiary of

TAFE, set up in 2006 when TAFE acquired Eicher tractors. The Eicher brand of
tractors has a distinguished heritage of 50 years in India. Known for its unique
distinction of offering a range of both air and water cooled tractors, its tractors
span the 24 to 60 HP range and have been well received in the segment. Eicher’s
less than 30 HP range has commanded market pre-eminence in the segment.
TAFE today is recognized as a high quality mass manufacturer with a extensive
product range to meet every farming need.

5150 368

485 242 5660

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 Vibration Analysis of Tractor fender Assembly and Test Correlation

Objective of case study:-

Tractor fenders are prone to failures because It is subjected to heavy dynamic
loads during various field Operation with implement such as Ploughing, Puddling,
Haulage etc. as well as in static condition (at idle RPM). To evaluate the structural
performance of tractor fender, it is necessary to determine "g‟ levels of
acceleration at fender mounting location. Also, once the test data is available, it
can be used for correlating it with the FEA results and then load history can be
used for reliable analysis to develop the product. The methodology helps in
moving towards virtual testing and to avoid/reduce physical testing of the sub-
systems to adhere to the constraints on time and cost.
Statement of problem:-

1. To carryout Static and dynamic analysis of Fender for structural strength

2. To correlate the test results ( shaker ) with FEA results.

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ACTUAL FIELD USAGES ANF RIG SIMULATION

Puddling

Rough Road

Haulage

Shaker

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Methodology

Experimental test FEM Modal Modal Test

measurements with Analysis Superposition Correlation
Various application Frequency
Response
Analysis

Final Design Design Iteration

Validation

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FE Modeling

The fender assembly components such as stiffener , brackets, canopy are made
of Structural steel of various grades. FE model has been developed by using pre-
processing software HyperMesh. Metal parts are modelled with shell elements
CQUAD and CTRIA by extracting mid surfaces . Bolted connections between two
components are modelled with CBEAM elements. The weld between each
component is modelled with shell elements of average of thickness. The masses
of individual parts and whole assembly were carefully cross checked for good
accuracy of frequency results. Back-rest

Stiffner
Fender
Fender Assembly
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Loadcases

Static Analysis
1. Vertical downward direction : Weight of 3 or 4 people
2. Braking load at back rest & Mudguard
3. Cornering load at back rest & Mudguard
4. Mudguard with Canopy

Dynamic analysis
1.Modal analysis – Natural Frequencies
2.Frequency Response Analysis to find effect of engine
vibration

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Frequency Response Analysis

This particular analysis was carried out to predict and reduce the road
induced vibration. The fender assembly where it is mounted was
considered for simulation. These boundary conditions were used for
both Modal as well as Frequency response analysis Here acceleration
derived from road load data is used to excite the assembly over an
operational frequency range as dynamic load. Stress and displacement
peaks are determined for the considered frequency range. This method
can be used to simulate and predict the actual response.

Frequencies below 10 Hz are not usually considered. The reason is that,

lowest idling rpm is usually above 600 rpm.

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 Field Failure Simulation

Actual field failure

Stress =144 Mpa

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Test Correlation

The simulation results are also well correlated by the experimental

results in which failure location and pattern is exactly matched. Further
modifications have been incorporated in design to meet the strength
requirement.

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Design Improvements

Different design iterations were analyzed as per the methodology, so as

to shift the natural frequency.

The 1st design proposal, weld location to be changed and increased to

50 mm from 30mm. It has natural frequency of 22 Hz, which results
same vibration levels as base design in frequency response analysis.

In case of 2nd design proposal, vertical Stiffener height to be increased

and welding location to be changed than the base design resulting in
significant reduction in vibration levels using frequency response
analysis.

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Analysis and Test Methodology

Initially modal analysis was carried out to estimate the natural

frequencies of the system. First 10 modes were extracted in this
analysis.

Acceleration were measured at different locations . Sensor locations on

were chosen such that maximum sensitivity was observed.

The measured acceleration Peak value on the fender at base locations

were in turn used for the Frequency Response analysis in Optistruct.

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 Loads and Boundary Conditions

Test Rig Set up

Constrained in all direction
FE Modeling as Per testing shaker setup
•Measured Acceleration data used for Resonance test at shaker table, Which
simulate the same field failure Zone.

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Design Improvements

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Experimental Test Set-up

The fender assembly is tested on shaker table test rig by mounting on

fixture at the bottom plate , with acceleration value generated from road
load data, over the operational frequency range.

Tri Axial accelerometer

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Benefits summary

Using FEA based Eigen frequency and frequency response analysis

techniques, the vibration characteristic of fender can be faithfully
replicated as observed in the physical test.

Multiple design proposals could be evaluated in virtual environment to

arrive at best and optimum design solution. The best design proposal
showed reduction in vibration level by 55.2%. Physical test on final
design reconfirmed simulation results and satisfactory performance of
the final design.

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Conclusion

Optistruct has been used to model and simulate the behavior of the
Fender Assembly for Vibrations. The results are matching closely with
the experimental test and required design modifications have been done
from analysis and iterations.

The work presented in this paper is in the early phases of ongoing work
and it is important to note these promising results will strongly demand
more detailed analysis for future projects.

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Acknowledgements/Credits

The authors would like to acknowledge our Design, Prototype and

testing teams for extending their kind support. The authors would also
like to thank the R&D Chief Mr. Hemant Shrikhande , and Testing Head
Mr. Suresh Gopal , Divisional Manager Design Mr. R.S. Kaushik Eicher
tractors for providing this opportunity for publishing the work.

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