Case
Study in upgrading the chassis through the use of Hydroformed
Parts in a 3 Wheeler
The
vehicle currently incorporates a conventionally
manufactured chassis using an ERW tube with
uniform cross section. A study was made to
determine the actual requirement, at different
points, and based on that an optimized design
proposed. The implementation of the revised
chassis is made possible by using hydroformed
parts.
Comparison between Existing Side Member and New
Side Member
The
existing side member utilized an ERW tube
40x80x2.6 mm.
The new side member would be one section
hydroformed to varying sections as per
design shown below and welded to another
ERW tube 40x80x2mm as shown below.
By making such changes in the
long members alone, There
was a net saving in weight of 8.85 kg/vehicle. ( on 2
members/vehicle) Uniform
stress pattern for side member Increase
in strength to weight ratio Improved
fuel efficiency
Comparison between Existing
and New Spleen pipe
CDS Tube Diameter-76.0
x 4 mm. thick
Total Weight per vehicle = 10.9 Kg.
ERW Tube Diameter
vary
from 76.0 to 62.0 mm x 4 mm. thick
Total Weight per vehicle = 9.78 Kg.
Saving in weight per vehicle = 1.12 Kg.
(Welding seam of ERW tube will be tested at 25000
psi in the Hydroforming process).
Total weight saving / vehicle = 9.97 kg.
Total cost saving / vehicle = Rs. 450
Depending on the chassis, it may be possible
to expand the scope to other cross members
as well with even higher resultant benefits.
There
was a net saving in weight of 8.85 kg/vehicle. ( on 2
members/vehicle)
