ABSTRACT
An axle is a central shaft for rotating wheels and is a crucial component in the functioning of wheeled vehicles. Depending on the design, an axle may rotate along with the wheels or remain stationary while the wheels rotate around it. In either configuration, the primary functions of an axle are to transmit driving torque to the wheels and maintain proper alignment between the wheels and the vehicle body. Moreover, axles are subjected to both static and dynamic loads, as they carry the full weight of the vehicle and any additional payload. The front axle beam, in particular, plays a vital role in the suspension system and integrates steering components. Given that it supports approximately 35 to 40 percent of the total vehicle weight, its structural integrity and proper design are essential for overall vehicle performance and safety.
The current research focuses on the design and analysis of a front axle for a heavy commercial vehicle equipped with an FA WT 6.5-ton front axle. The project was executed in two key phases. In the first phase, an analytical design method was employed using the vehicle’s specifications, including gross weight and payload capacity, to calculate the expected stresses and deflections in the axle beam. In the second phase, the axle was modeled using CATIA software and subjected to static and dynamic analysis in ANSYS to simulate real-world operating conditions. The finite element (FE) results obtained from ANSYS were then compared with the outcomes of the analytical calculations to validate the design approach and ensure structural reliability.
A significant aspect of this study involves the assessment of vibrational behavior, particularly resonance, which occurs when the natural frequency of a component matches its excitation frequency. This phenomenon can lead to excessive deformation and potential failure in moving vehicle components like the front axle. To mitigate such effects, a damper was introduced into the system. The study investigates the axle’s performance with and without the damper, revealing that the use of a damper substantially reduces resonance-induced deformation. As a result, the overall durability and lifespan of the axle are enhanced. The findings underscore the importance of incorporating damping elements in axle design to improve vibration resistance and structural longevity.