International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.

57 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

DESIGN AND PRE MANUFACTURING ANALYSIS OF STUB AXLE HOUSING

a
Johny James .S*, bAmarnath.P, cSanthosham.M, dA.Haiter Lenin
a, b, c
Mechanical Engineering, Kingston Engineering College, Vellore, 632059, India
d
Professor, PET Engineering College, Vallioor, 627117, India
Email: johnyjames2002@yahoo.com
Phone: 9443711170

Abstract:
In this research article analysis has been carried out to investigate the mechanical properties and
the simulation has been done for the manufacturing the stub axle housing. In this Analysis the stub axle
housing made up of Aluminum 6063 - T6. The static structural torque analysis was carried out, the stress,
strain concentration in the stub axle housing in the different regions were analyzed. In this paper, the
model was subjected to Vibration modal Analysis to determine the behavior of the Stub axle housing with
varying frequencies. This paper also deals with the estimation of manufacturing time using Arena
Software.

Keywords: Stub axle Housing, Arena, Torque Analysis and Modal Analysis

Introduction:

Stub axle Housing: Stub axle housing is the Link which is connected between the tie rod and the front
wheel assembly [1].

Figure 1: Represents the Assembled view of Stub axle housing with front axle system

Front Axle: A front axle assembly is the unit that connects two wheels at the front of a vehicle, and
allows those wheels to rotate freely and sometimes independently. Very simple
front axle assembly models may not include much beyond the axle, axle housing, and bearings to allow
the axle itself to rotate, while other assemblies that are more complex may include steering and
suspension components [1].

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Torque Analysis: Torque, moment or moment of force (see the terminology below), is the tendency of a
force to rotate an object about an axis, torque is defined as the cross product of the lever-arm distance and
force, which tends to produce rotation. This stub axle housing experiences the torque or twisting moment
[2].

Modal Analysis: Modal analysis is the study of the dynamic properties of structures under Vibration
excitation. Modal analysis is the field of measuring and analyzing the dynamic response of structures and
or fluids when excited by an input [6].

Arena: In Arena, the user builds an experiment model by placing modules (boxes of different shapes)
that represent processes or logic. Connector lines are used to join these modules together and specify the
flow of entities. While modules have specific actions relative to entities, flow, and timing, the precise
representation of each module and entity relative to real-life objects is subject to the modeler. Statistical
data, such as cycle time and WIP (work in process) levels, can be recorded and outputted as reports.

The flagship product provides the ultimate in functionality and flexibility to meet the needs of
any simulation problem. Systems, regardless of complexity, can be represented and custom performance
metrics may be measured and tracked. Included is the functionality of Opt Quest, for optimizing systems,
as well as the additional capability of object and template development.

In this project the manufacturing sequence has been modeled and simulated with providing initial
entities to estimate the time for the manufacturing the products from converting the raw material to the
finished stage. For this simulation purpose the Academic software edition of Arena was utilized to
determine the time for processing the raw material to finished state[13].

Design and Analysis of Stub Axle housing:

Figure 2: Represents the Stub axle housing model created by Solid works

This part was designed with the help of Solid Works 2012. Also the same solid work 2012 was
used for the Static structural analysis for determine the Torque effect on the stub axle housing as well as
the modal analysis also been carried out by the help of this software.

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.57 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

Torque Analysis of the Stub Axle Housing:

Figure 3: Represents the Stub axle housing model applied with torque loads.

The torque analysis on the stub axle has been carried out by constraining the hollow cylindrical
inner region. The torque moment applied on the stub axle housing was 15 N-m.

Parameters for Analysis of Stub Axle Housing:

Name: 6063-T6
Model type: Linear Elastic Isotropic
Default failure criterion: Unknown
Yield strength: 2.15e+008 N/m^2
Tensile strength: 2.4e+008 N/m^2
Elastic modulus: 6.9e+010 N/m^2
Poisson's ratio: 0.33
Mass density: 2700 kg/m^3
Shear modulus: 2.58e+010 N/m^2
Thermal expansion 2.3e-005 /Kelvin
coefficient:

Figure5: represents the stress in the Stub axle

Figure 4: Represents meshed models of Stub axle housing the Maximum stain is 4.70909e+006 N/m^2
Node: 2035

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© Research India Publications; httpwww.ripublication.comijaer.htm

Figure6: Represents the displacement in the Stub Figure7: Represents the strain in the Stub axle
axle housing the Maximum stain is 0.0340981 mm housing the Maximum stain is 4.19707e-005
Node: 3610 Element: 954

Modal Analysis of the Stub axle housing:

Frequency Number Rad/sec Hertz Seconds

1 4424.9 704.25 0.00142

2 8368.4 1331.9 0.00075082

3 19452 3095.9 0.000323

4 26809 4266.7 0.00023437

5 38293 6094.5 0.00016408

Figure8: Displacement 1 Figure9: Displacement 2

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Figure10: Displacement 3 Figure11: Displacement 4

Figure12: Displacement 5
The Modal analysis was carried out on the stub axle housing modal shape obtained for the
frequency set 4 causes more twist in the model.

Simulation Using Arena:

Table:1 The delay chosen for this analysis is constant

Number Busy Average Half Width Minimum Maximum Minimum Maximum

Average Average Value Value

casting 1.0000 0.00 1.0000 1.0000 0.00 1.0000

drilling 1.0000 0.00 1.0000 1.0000 0.00 1.0000
surface grinding 1.0000 0.00 1.0000 1.0000 0.00 1.0000

Waiting Time Minimum Maximum Minimum Maximum

Average Half Width Average Average Value Value
Process 1.Queue 681 95.37 40.8620 55.8742 28.1704 72.5176
48
.
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Average Minimum Maximum

Scheduled Utilization Half Width Average Average
casting 1.0000 0.00 1.0000 1.0000
Drilling 1.0000 0.00 1.0000 1.0000
Surface grinding 1.0000 0.00 1.0000 1.0000

Total Number siezed Avera Half Average Average

ge Width
Casting 2.00 0.00 2.0000 2.0000
Drilling 00
2.00 0.00 2.0000 2.0000
Surface grinding 00
2.00 0.00 2.0000 2.0000
00

Figure13: Total Number seized

Using Arena simulation the finally results after simulation has been plotted in the graph format.
Finally the Total time in queue has been identified as,

Number Waiting Minimum Maximum Minimum Maximum

Aveerage Half Width Average Average Value Value
Process 1.Queue 2. 182 23.49 0.4695 4.1668 0.00 5.0000

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.57 (2015)
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Conclusion:

Pre manufacturing analysis helps to identify the overall process involved in the manufacturing of
Stub axle housing, to predict the operation involved and the time carried out in the manufacturing the
product. By analyzing the model for vibration helps the designers to predict the Design parameters and
necessary changes in the Design modification of the parameters before manufacturing the product which
leads to ultimate reduction in time reduction.

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