A computational model-based prediction approach for truck chassis strength deviation range

• A multibody dynamics simulation is used to estimate the truck reaction force. • A truck chassis strength analysis model performed with the finite element method (FEM) combined with an inertia compensation technique. • A design of experiment (DOE) technique with an FEM model is employed to predict the response deflection of the structure due to deviation of structural parameters. • The proposed computer model exhibits high reliability and is suitable for analyzing the truck chassis strength deviation. • The maximum deflection stress value is equivalent to 3.75 %, while the displacement is equivalent to 3.15 %. Analysis of truck chassis strength is an important aspect of the truck design process. For an experimental study, the measurements might be considered complex and expensive, with multiple prototypes required. To overcome this existing situation, a computational method is proposed for the analysis of the truck chassis strength deviation. In this study, multiple calculations were performed: (1) a multibody dynamics simulation used to replace experiments in determining the truck reaction force; (2) a truck chassis strength analysis model performed with the finite element method (FEM) combined with an inertia compensation technique; and (3) a design of experiment technique with an FEM model to predict the response deflection of the structure due to deviation of structural parameters. The analysis using the HyperStudy solver was verified against a mathematical model to increase confidence in the simulation results. The result shows the reliability of the OptiStruct solver and the HyperStudy models were about 98.66 % and 98.39 % compared to that of the verified mathematical model, respectively. The validation results exhibit that the maximum deviation between the HyperStudy computational model and the mathematical model is from 5.85 to 6.16 mm for the thickness variable, corresponding to 1.61 %. For the elastic modulus E , varying from 193,820 MPa to 213,447 MPa gives a maximum deviation of 1.54 %. The proposed computational model proves to be highly reliable and suitable for analyzing the truck chassis strength deviation. The variation in thickness and Young's modulus within the tolerance range does not show any adverse effect on the chassis strength. The maximum deflection stress value is equivalent to 3.75 %, while the displacement is equivalent to 3.15 %.