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Slider Frame Plating Stress test?

Discussion in 'Off-Roading & Trails' started by 01tacoprerunner, Feb 10, 2011.

  1. Feb 10, 2011 at 8:22 PM
    #1
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    Found it:

    Copied from NWTOYS.com Member: tcmaboy

    Not my work all his ^

    Slider mounting
    Carried over from WATTORA

    The following are stress analyses of various slider mounting methods. This does not address any specific design, but rather general concepts.

    Modeling was done in SolidWorks and analysis was done using COSMOSWorks. It was assumed that all parts are welded so solid bodies, not assemblies, were modeled. The material specified was mild steel.

    It was assumed that the largest loading a slider will experience is a vertical load as a result of a truck sliding off an obstacle and impacting an object. The load applied in the model is based on an assumption that the load is distributed among many mounting legs. To simplify modeling a single leg was simulated and an appropriate fraction of the load was applied.

    Method 1: Diamond shaped plates.

    The slider is mounted using a diamond shaped plate attached to the outer wall of the frame rail. This method places the welds at 45 degree angles to the frame which allows the load to be spread over all of the welded surfaces. Each welded side will experience less stress, however there is a large stress concentration at the upper and lower corners of the plate.

    [​IMG]

    Method 2: Square shaped plates.

    The slider is mounted with a square plate to the outer wall of the frame rail. With this method only two of the four weld surfaces will be placed under a load. Each individual weld will experience higher loading, however the stress concentration that results from the diamond mounting method is eliminated and the peak loading that the plate experiences is lower than the peak loading that results at the corners of the diamond method.

    [​IMG]

    Method 3: Leg through frame.

    A hole is drilled through both walls of the frame and the leg is inserted and welded to both walls. This method spreads the load across both walls of the frame. Spreading the load over a larger portion of the frame significantly lowers the stress at any given point in the frame walls. With this method there are no sharp corners that result in stress concentrations.

    [​IMG]

    Design refinements.

    Rounding off corners will reduce the stress concentration at that point. The larger the radius the greater the reduction in stress.

    Mounting methods that include both walls of the frame are preferable to those that only use the outside wall.

    Larger plates will spread the load over a larger area.

    Gusseting the legs will reduce the stress at the base of the leg where it meets the mounting point. The load will be transfered to the point where the gusset meets the frame.

    [​IMG]


    [​IMG]
     
  2. Feb 10, 2011 at 8:45 PM
    #2
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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  3. Feb 11, 2011 at 2:20 PM
    #3
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    I found it check this out!
     
  4. Feb 11, 2011 at 2:37 PM
    #4
    ktmrider

    ktmrider Senior Member

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  5. Feb 11, 2011 at 2:39 PM
    #5
    FlawedXJ

    FlawedXJ mall crawlin', web wheelin', concrete cowboy

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    good stuff. If i still had a solidworks license i'd do some FEA on bolted vs weld on options.
     
  6. Feb 11, 2011 at 2:41 PM
    #6
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    Yea i wish i knew how to run it cause we have it at school, and i would use it to do some testing too.
     
  7. Feb 11, 2011 at 2:46 PM
    #7
    mustangwilly

    mustangwilly Well-Known Member

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    Still need to run a true stress test with stress coat and strain gauges to verify the FEA. Anyone have a Edaq handy?
     
  8. Feb 11, 2011 at 2:46 PM
    #8
    FlawedXJ

    FlawedXJ mall crawlin', web wheelin', concrete cowboy

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    what edition/year/version. it isn't called cosmoworks anymore. An analysis like that is one of the most basic simplest to do. Solidworks will have built in tutorials good enough to cover something of that nature.
     
  9. Feb 11, 2011 at 2:49 PM
    #9
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    Dont know what that means


    Its probably one of the most up to date versions. They keep everything pretty new at my school.
     
  10. Feb 11, 2011 at 2:49 PM
    #10
    FlawedXJ

    FlawedXJ mall crawlin', web wheelin', concrete cowboy

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    I actually have a jeep now. Imagine that.
    I'm sure you could just run the analysis with a higher load value to modify the FOS. I have a copy of ansys that I could try and screw around with.

    By Strain gages do you mean the wye-circuit style ones? like measuring deformation by resistance changes? been a while since i've toyed with those.
     
  11. Feb 11, 2011 at 3:03 PM
    #11
    mustangwilly

    mustangwilly Well-Known Member

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    I was just being a smart ass! Here's what we would use for that application.
    http://www.vishaypg.com/micro-measurements/stress-analysis-strain-gages/
     
  12. Feb 11, 2011 at 3:27 PM
    #12
    FlawedXJ

    FlawedXJ mall crawlin', web wheelin', concrete cowboy

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    Ok good haha. I seriously thought you were suggesting blowing hundreds of dollars on strain gages lol
     
  13. Feb 12, 2011 at 4:01 PM
    #13
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    Bump good info.
     
  14. Feb 12, 2011 at 4:06 PM
    #14
    Timicha

    Timicha Timicha

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    Fabtech 4 inch lift, tinted windows, diff drop, 33 inch MTZ tires on Raceline Raptor wheels, ELITE OFF-ROAD bumpers and sliders
    That's pretty awesome. Nice find man
     
  15. Feb 23, 2011 at 9:55 PM
    #15
    01tacoprerunner

    01tacoprerunner [OP] Lifted 'n Locked 4WD Prerunner

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    bump bump bump
     
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