This report is for general information only. The material contained herein
should not be used without first securing competent advice with respect to
its suitability for any given application. This report is not intended as a
representation or warranty on the part of Auto/Steel Partnership or any
other person named herein that the information is suitable for any
general or particular use, or free from infringement of any patent or
patents. Anyone making use of the information assumes all liability arising
from such use.
October 1, 2003
Prepared For:
Auto/Steel Partnership
Prepared By:
Background
Designing a light truck frame joint with the correct stiffness is always a challenging proposition for frame
designers. A survey of current production frames found that most frames used joint styles from a group of
approximately fifteen joints. Frame designers see some merit in using these same joint styles, but the
information regarding these joint styles is either not well documented or is not available to others in a
useful format. The ASP Lightweight SUV Frames Project Team felt that a study to determine the relative
stiffness of the joints, along with a tool to communicate the results of the study to frame designers, would
allow for better decision-making in the concept phase and would facilitate lighter weight frame designs.
This study is divided into two phases, Phase 1 and Phase 2. The Phase 1 study, which has already been
completed, is comprised of five joints. A project report for the Phase 1 study has been published [1] and
is available on the ASP website [5]. An Excel Spreadsheet Toolbox [2] was also developed in Phase 1
and it too is available on the A/SP website. The Phase 2 study is a continuation of the Phase 1 study,
and it is comprised of ten additional joints. This report presents information developed in the Phase 2
study.
Project Goals
The goal of the Phase 2 study was to provide frame designers with the same objective data and tools
used in Phase 1 to facilitate early concept choices for ten additional frame joints.
In order to achieve the goals, the scope of the project involves the following steps:
Project Results
The testing and finite element analysis processes followed to evaluate the stiffness of the ten joints was
similar to the Phase 1 study. An interactive Joint Stiffness Toolbox was developed to document the study
results, and to provide a mechanism for frame designers to use the data in the design process. The
Toolbox is based on an interactive worksheet. The spreadsheet allows the designer or engineer to
modify the geometric and gage properties of the joint members and calculates the joint stiffness and
relative mass based on the new properties.
Preface ....................................................................................................................................... i
Executive Summary................................................................................................................. ii
Table of Contents.................................................................................................................... iii
List of Tables........................................................................................................................... iv
List of Figures .......................................................................................................................... v
Acknowledgments ................................................................................................................... x
Phase 2 Joints Summary ........................................................................................................ 1
Riveted Joint Testing............................................................................................................... 5
Introduction .................................................................................................................... 5
Test Specimen (Joint) Description ................................................................................. 5
Test Specimen (Joint) Preparation............................................................................... 11
Test Joint Fixturing ....................................................................................................... 12
Test Joint Deflection Measurement.............................................................................. 15
Test Joint Force Application......................................................................................... 15
Joint 6 Testing.............................................................................................................. 16
Joint 7 Testing.............................................................................................................. 19
Repeatability of Riveted Joints..................................................................................... 21
Rivet Diagnostic Testing .............................................................................................. 21
Riveted Joint Correlation ...................................................................................................... 31
Introduction .................................................................................................................. 31
Initial FEA Models ........................................................................................................ 31
Model Changes to Improve Correlation ....................................................................... 33
Final FEA Models......................................................................................................... 34
Final Correlation between FEA and Test Data............................................................. 36
Joint Stiffness Summary....................................................................................................... 38
Sensitivity Study .................................................................................................................... 41
Introduction .................................................................................................................. 41
Study Models ............................................................................................................... 41
Joint Parameters .......................................................................................................... 41
Toolbox ................................................................................................................................... 75
Introduction .................................................................................................................. 75
Bi-linear Stiffness for Riveted Joints 6 and 7 ............................................................... 75
References.............................................................................................................................. 97
Appendix A: Test Data Plots ................................................................................................. 98
Appendix B: Design Variables ............................................................................................ 104
Appendix C: Screening DOE Study.................................................................................... 114
Appendix D: Phase 1 Joint 2A DOE ................................................................................... 120
Appendix E: Material Test Results ..................................................................................... 129
Appendix F: Phase 2 Joints Description ........................................................................... 134
Altair would like to make special mention of the following who provided the test joints and CAD data used
in Phase 2:
Figure 5: Joint 10: Rectangular Tube Section through Rectangular Tube Section
Figure 6: Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section
Figure 8: Joint 13: Full Height Channel Section to Rectangular Tube Section
Figure 9: Joint 14: Full Height Rectangular Tube Section to Rectangular Tube Section
Figure 10: Joint 15: Full Height Channel Section to Channel Section
Introduction
Two riveted joints (displayed in Figure 11 and Figure 12) were chosen for testing in Phase 2. The Team
was confident that welded joints would correlate well based on its experience in Phase 1, but wanted
correlation for the two riveted joints. Three samples of each of the two riveted joints were tested to
determine the load versus deflection curve using the procedure developed in Phase 1 and documented in
SAE Paper 2003-01-0241 [3]. The test results are summarized in stiffness Table 1 (see page number
30).
Figure 11: Joint 6: Hat Section to Channel Section (finite element representation)
Figure 12: Joint 7: Hat Section (with Bracket) to Twin Channel Sections (finite element representation)
Side Rail
Brackets
Crossmember
Figure 13: Joint 6: Hat Section to Channel Section Physical Representation (isometric view)
Figure 13 displays the sub-components of the riveted Joint 6. The main sub-components are the side rail
and crossmember. These two sub-components are joined together using four rivets. The End Plates
displayed are part of the test set-up and are used to hold the joint in place when applying the loads.
Figure 15 displays a close-up view of the rivet attachments between the side rail and crossmember.
Brackets
Side Rail
Figure 14: Joint 6: Hat Section to Channel Section Physical Representation (rear view)
Side Rail
Rivets
(attachment
between
crossmember and
side rail)
Crossmember
Figure 16: Joint 7: Hat Section (with Bracket) to Twin Channel Sections Physical Representation (front
view)
Figure 16 displays the sub-components of the riveted Joint 7. The main sub-components are the
following: inner side rail, outer side rail, upper crossmember and outer crossmember. The inner and outer
side rails are welded together, as displayed in the figure. This figure also displays the upper welds, but
similar welds are in the bottom too (not seen in the picture). The upper and lower crossmembers are
welded together, as displayed in the figure. The side rails and crossmembers are attached together with
six rivets. Figure 18 displays the rivet attachment scheme employed in attaching the side rails and the
crossmembers. The End Plates displayed are part of the test set-up and are used to hold the joint in
place when applying the loads.
End Plates
(part of the test
set up)
Figure 17: Joint 7: Hat Section (with Bracket) to Twin Channel Sections Physical Representation (rear
view)
Rivets (between
side rails and
crossmember
Upper
Crossmember
Lower
Crossmember
Figure 18: Joint 7: Hat Section (with Bracket) to Twin Channel Sections Rivet Attachments
Crossmember
Rough-cut mark
Side Rail
Figure 20 and Figure 21 display the complete test set up for the fore-aft and torsional loadcases. The test
set up for the vertical loadcase was identical to the fore-aft loadcase, except that the load was applied in
a different direction.
Fore-Aft load
application point
for that loadcase
Measurement
fixture
LVDTs to measure
displacements
Joint
Figure 20: Joint 7: Hat Section (with Bracket) to Twin Channel Sections Fore-Aft Loading Setup
Figure 20 displays the typical test set up employed for the Fore-Aft loadcase. Also displayed in the
picture is the measurement fixture used for measuring the displacement corresponding to the loadcase.
Linear Variable Displacement Transducers (LVDTs) were used to measure the displacement. The test
set up for the Vertical loadcase is identical to the Fore-Aft loadcase. In the vertical loadcase, however,
the load is applied at a different point in the test fixture as displayed in the above figure. Also, the LVDTs
are located such that vertical displacements are measured.
Torsional load
(using two
pneumatic
cylinders)
Measurement
fixture
Joint
Figure 21: Joint 7: Hat Section (with Bracket) to Twin Channel Sections Torsional Loading Setup
Figure 21 displays the typical test set up employed for the Torsional loadcase. Also displayed in the
picture is the measurement fixture used for measuring the displacement corresponding to the loadcase.
Linear Variable Displacement Transducers (LVDTs) were used to measure the displacement.
Torsional load
application
Bar for measuring
fore-aft and vertical
deflections
Vertical load
application
point
Plate bolted to
the joint
Fore-Aft load
application point
Figure 22 displays a close up of the measurement fixture used for the joint testing. This measurement
fixture is bolted to the joints along with the load application set up. LVDTs are fastened to this fixture to
measure displacement.
The test results were evaluated for repeatability. Figure 23 displays the test data for Joint 6 in the Fore-
Aft loadcase. Three samples of Joint 6 were tested and three tests were conducted on each sample.
Test Data
(3 samples
and 3 tests for
each sample)
Test DataLinear
Average - Average Linear
Fit Test DataFit
Analysis Data
Figure 24: Joint 6 Fore-Aft Loadcase Analysis and Test Data Comparison
Analysis Data
Figure 25: Joint 6 Vertical Loadcase Analysis and Test Data Comparison
Test Data
(3 samples and 3 tests for
each sample)
Analysis Data
Figure 27: Joint 7 Vertical Loadcase Analysis and Test Data Comparison
Figure 27 displays the comparison between analysis data and average linear fit test data for Joint 7 in the
Vertical loadcase.
Test Data
Analysis Data
Figure 28: Joint 7 Vertical Loadcase Analysis and Test Data Comparison
Figure 28 displays the test data, average linear fit test data and analysis data of the Vertical loadcase for
Joint 7.
Section - A
Section - B
Section - C
In total, there are nine curves (three samples and three tests per sample) displayed in Figure 29.
Although test-to-test variation (per sample) is insignificant, sample-to-sample variation is significant. The
curves in Figure 29 are delineated into three sections, A, B and C. Section A and C correspond to the
extremeties of loading and Section B corresponds to the on-center loading. Moreoever, Section A relates
to the negative loading direction and Section C relates to the positive loading direction.
The following points are noted based on the observation of the test data displayed in Figure 29.
Section B indicates that the slope in the +/- 1000N load range is not consistent with the slopes
beyond that range. The higher slope indicates that the samples are more compliant. Compliant is
defined as the ratio of resultant displacement to the applied force, i.e., high compliance implies that
the joint displaces more for a given amount of force than a less compliant joint. In other words,
compliance is the inverse of stiffness.
This behavior was identified more in the Fore-Aft loadcase than in the other two loadcases for both joints.
With significant differences as illustrated in Figure 29, it was evident that further diagnostic testing was
requried to better characterize the joint behavior. To understand the underlying phenomenon, one joint
sample was chosen and tested. The joint sample chosen was Sample-3 of Joint 7 and the loadcase
chosen was Fore-Aft.
Five of the six rivets in Joint 7 (sample 3) were instrumented to track the deflection of the rivets in each of
the three directions (X, Y and Z) during the test. Figure 30 shows the five rivets that were tracked during
the test. The test setup used was identical to the previous testing and the Fore-Aft loadcase was
selected because of the significant variations observed in that loadcase. The sixth rivet could not be
observed because of physical constraints.
Test results were plotted for displacements of the rivet, crossmember and side rail inner at two areas, U
and V, illustrated in Figure 30. Figure 31, Figure 32 and Figure 33, respectively, show the X, Y and Z
direction displacement of the rivets, the crossmember and the side rail inner at area-V. In Figure 33,
X
C2
C1
C3
RIVET
CROSSMEMBER
SIDE RAIL
Y
C2
C1
RIVET
CROSSMEMBER
SIDE RAIL C3
RIVET Z
CROSSMEMBER
SIDE RAIL
C2
C3
C1
In Figure 31 throught Figure 33, the curve "C3" (red-colored) represents the displacement of rivet; the
curve "C2" (green-colored) represents the displacement of the crossmember; and, the curve "C1" (blue-
colored) represents the displacement of side rail inner.
Observing the X-direction displacement data, it is clear that the rivet and side rails do not displace as
much as the crossmember. The crossmember not only moves independent of the other two but also has
significantly more displacement than the others. Observing the same behavior in Y-direction
displacement data, it is also clear that the rivet and crossmember move significantly more than the side
rail inner does. It is noted here that the X and Y direction displacements are a direct result of the
compliance that exists between the rivet, crossmember and side rail inner. However, the Z-direction
displacement of all the three components are consistent with each other. Since the Fore-Aft load is
applied via the crossmember, this additional compliance in the crossmember translates into additional
deflection of the joint, resulting in lower joint stiffness values in that direction.
Similar behavior is observed at Area U (see Figure 30) of Joint 7 in the Fore-Aft loadcase. Figure 37
displays the X, Y and Z direction displacement test data of the rivet, crossmember and side rail inner at
area U of the joint. The other rivet areas did not show significant differences in displacement.
The results were shown to an experienced frame engineer, who looked at the test results and explained
that the rivet typically does not expand into the entire hole in all of the riveted joints, due to normal
manufacturing variations. Figure 34 illustrates the variations seen in the rivet expansion inside the rivet
hole in typical riveted joints.
RIVET X
CROSSMEMBER
SIDE RAIL
C2
C1
C3
RIVET Y
CROSSMEMBER
SIDE RAIL C2
C3
C1
Z
C2
C1
C3
RIVET
CROSSMEMBER
SIDE RAIL
Though a real world joint will exhibit this slip behavior, the finite element analysis does not capture this
slip mechanism. The test joint stiffness is lower than the finite element data because of the additional
compliance in the test joints in the +/- 1000N load range. The test data in the area "off-center" does
agree with the finite element data. This behavior was expected by the Team when the riveted joints were
added to the matrix. This test work is the first public riveted joint stiffness test data that the team is aware
of.
Based on this information, the stiffness for some of the loadcases of the two joints were recalculated. As
noted, the slopes of the negative and positive load directions beyond the +/- 1000N range are consistent
with each other. Therefore, this slope was used to compute the stiffness and was compared to the
stiffness from the finite element analysis (see section on Riveted Joint Correlation). The resultant
comparison produced better correlation between the test data and finite element analysis. See A/SP
Phase 1 [1] report to understand the formulae employed to compute the stiffness. Table 1 presents the
initial and final stiffnesses of Joints 6 and 7.
Introduction
Finite element analysis (FEA) techniques were used to demonstrate the correlation of each joint.
Correlation was attemped for Joints 6 and 7 between the finite element models and test data. The finite
element model was created using the CAD data that was supplied. The CAD data was checked against
the actual dimensions of the test sample joints to establish dimensional validity of the CAD data. An initial
finite element model was created using 2D shell elements (quad and tria types) and 1D rigid elements.
The 1D rigid elements were used to establish the riveted connection between the crossmember, siderail
and other components. This type of representaion assumes that no relative motion can occur between
the components in the riveted joints. Later, for a more accurate representation of the rivets themselves,
3D solid elements were used in the finite element models.
Crossmember
Side Rail
Bracket
Bracket
Bracket
Upper Crossmember
The initial finite element models developed for the two joints (6 and 7) were in close agreement with the
joint samples established for testing. The rivets were modeled using 1D rigid elements. Figure 40 shows
a close-up view of the rivet modeling technique employed in the initial finite element model for both the
joints.
Component - A
Component - B
(Transparent color)
Rivet attachments
using 1D rigid
elements
In this figure, components A and B are attached together using a rivet. The circular rivet hole is
approximated as a hexagon, which is valid for finite element analysis. Each perpendicular node on
component-A (shown in green color) is directly connected to the corresponding node on component-B
(shown in transparent color) using 1D rigid elements. This type of modeling technique does not allow for
any slippage to occur between the various components or for slippage to occur between the rivets and
the components. Table 2 and Table 3 display the stiffness results for the finite element analysis and test
samples. The nine curves (three tests for each sample and three samples for each joint) were averaged,
and the slope of this averaged curve was reported as stiffness for each of the joint test samples.
Table 2: Joint 6 Stiffness Comparison between Initial FEA and Test Data
LOADCASE ANALYSIS TEST DEVIATION
Fore-Aft (Kz stiffness, kN-m/deg) 24.18 14.36 41%
Table 3: Joint 7 Stiffness Comparison between Initial FEA and Test Data
LOADCASE ANALYSIS TEST DEVIATION
Fore-Aft (Kz stiffness, kN-m/deg) 34.98 13.81 61%
Further analysis was performed on both the joints to demonstrate the effects from the boundary
conditions variation or effects from not applying loads at the shear center. All analyses for both the joints
pointed to the fact that there was no significant improvement in correlation between the analysis and test
data. The only possible area remaining for improvement was the rivets themselves, since the rivets were
idealized in the initial FEA model. Therefore, more information was requested on the rivets in order to
improve modeling accuracy and to increase correlation. The rivet and its hole dimensions were obtained
from the rivet manufacturer and the rivet processing techniques were understood. The relevant rivet
dimensions for the Joints 6 and 7 are displayed in Table 4.
Rivet (modeled
using 3D solid
elements)
1D rigid element
Component - A for attachment
Component - B
Figure 43, below, displays the 3D solid model of the rivet used in the analyses to improve correlation.
This figure shows only the rivet and the rivet holes are in the individual components that make up the
joint. The 3D rivet model fits inside the rivet holes with attachments to the individual components at those
points shown by RBE2 elements. These RBE2 elements establish rigid connection between the 3D rivet
and the individual components of the joint.
Rivet Diameter
Rivet Height
Figure 42: Rivet 3D-Solid Elements used in the Final FEA model
Rivet Diameter
Rivet Height
Table 5: Joint 6 Stiffness Comparison between Final FEA and Test Data
LOADCASE ANALYSIS TEST DEVIATION
Fore-Aft (Kz stiffness, kN-m/deg) 22.09 22.06 0.12%
Table 6: Joint 7 Stiffness Comparison between Final FEA and Test Data
LOADCASE ANALYSIS TEST DEVIATION
Fore-Aft (Kz stiffness, kN-m/deg) 30.64 26.71 13%
The correlation was good between the final FEA models and the test data. As indicated in the Phase 1
report, deviations of up to thirty percent are acceptable. In the two joints considered here, the percentage
deviation between analysis and test data is well under thirty percent.
It is noted here that the stiffnesses from testing for Joints 6 and 7 were recomputed. The information
presented in the Rivet Diagnostic Testing sub-section (see Riveted Joint Testing section) explains why
the stiffnesses for the test data were recomputed. Referring to Table 2, Table 3, Table 5 and Table 6 (all
four stiffness tables), the Fore-Aft loadcase test stiffnesses were recomputed for both the joints and the
Vertical loadcase test stiffness was recomputed for Joint 7 only. The Torsional loadcase stiffnesses
correlated well with the finite element data, and therefore it was not recomputed for both the joints.
The following section presents the joint stiffness results for all the eleven joints considered in this study.
z), vertical (K
The three stiffness values correspond to the fore-aft (K x) and torsional (K
y) loadcases.
Analysis:
Joint 7: Hat Section (with Bracket) to Twin
Channel Sections K2 = 30.64 K2 = 4.44 K2 = 2.14
Introduction
An important requirement of the study was to establish a set of frame joint Design Rules. By using FEA,
we were able to establish guidelines for the ten joint types included in Phase 2 of the study. The designer
will be able to use the Design Rules to predict the stiffness of a joint that is similar to one of the ten types
in the study.
Study Models
To normalize the joints for the sensitivity study, the joint models needed to be modified. Geometric factors
of the joints surrounding structure were removed to eliminate its influence on the joint stiffness. These
changes included straightening out the crossmember and side rail. Figure 44 shows the modified joint
geometry compared to the original for Joint 6.
Figure 44: Example of Original Joint 6 Geometry (left) vs. Modified Joint 6 Geometry for Study (right)
The study models for the ten joints in Phase 2 are shown in Appendix B. Joint 2, included in Phase 1 of
the study, was slightly simplified as explained in Appendix D. A study model was prepared for the
simplified joint (Joint 2A). The study model for Joint 2A is shown in Appendix D.
Joint Parameters
The joint parameter variables are component thickness and shape. The thickness of each of the joint
components is allowed to vary within a certain range for each joint. The shape variables include:
Crossmember height
Crossmember width
Flange width
An initial screening study was conducted to determine the key parameters. That is, the ones having the
greatest effect on stiffness (Appendix C). The influence of the key parameters on the stiffness of each
joint for each load case is shown in Figure 45 through Figure 77. For each plot, the Y-axis shows the
relative stiffness. The X-axis, for each component listed, shows how the stiffness varied over the range of
values allowed for each parameter. For example, the point furthest left of a parameters plotted line
would be the minimal allowed value for that parameter, and the point furthest right of the line would be the
stiffness at the upper value for the specified parameter. For the crossmember thickness in Figure 45, the
stiffness is 39 when the crossmember thickness is lowest at 2mm and the stiffness of the joint is 60 when
the crossmember thickness is 5 mm.
z
Stiffness K
Large Influence
on Stiffness
Small Influence on
Stiffness
Figure 45: Main Effect Plot for Joint 6: Hat Section to Channel Section Stiffness Kz
x
Stiffness K
Figure 46: Main Effect Plot for Joint 6: Hat Section to Channel Section Stiffness Kx
y
Stiffness K
Figure 47: Main Effect Plot for Joint 6: Hat Section to Channel Section Stiffness Ky
z
Stiffness K
Figure 48: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Kz
(Design Variables from 1 through 7)
x
Stiffness K
Figure 49: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Kx
(Design Variables from 1 through 7)
y
Stiffness K
Figure 50: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Ky
(Design Variables from 1 through 7)
z
Stiffness K
Figure 51: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Kz
(Design Variables from 8 through 15)
x
Stiffness K
Figure 52: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Kx
(Design Variables from 8 through 15)
y
Stiffness K
Figure 53: Main Effect Plot for Joint 7: Hat Section (with Bracket) to Twin Channel Sections Stiffness Ky
(Design Variables from 8 through 15)
z
Stiffness K
Figure 54: Main Effect Plot for Joint 8: Rectangular Tube Section to Rectangular Tube Section Stiffness
Kz
x
Stiffness K
Figure 55: Main Effect Plot for Joint 8: Rectangular Tube Section to Rectangular Tube Section Stiffness
Kx
y
Stiffness K
Figure 56: Main Effect Plot for Joint 8: Rectangular Tube Section to Rectangular Tube Section Stiffness
Ky
z
Stiffness K
Figure 57: Main Effect Plot for Joint 9: Circular Tube Section through Channel Section Stiffness Kz
x
Stiffness K
Figure 58: Main Effect Plot for Joint 9: Circular Tube Section through Channel Section Stiffness Kx
y
Stiffness K
Figure 59: Main Effect Plot for Joint 9: Circular Tube Section through Channel Section Stiffness Ky
z
Stiffness K
Figure 60: Main Effect Plot for Joint 10: Rectangular Tube Section Through Rectangular Tube Section
Stiffness Kz
x
Stiffness K
Figure 61: Main Effect Plot for Joint 10: Rectangular Tube Section Through Rectangular Tube Section
Stiffness Kx
y
Stiffness K
Figure 62: Main Effect Plot for Joint 10: Rectangular Tube Section Through Rectangular Tube Section
Stiffness Ky
y
Stiffness K
Figure 63: Main Effect Plot for Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section
Stiffness Kz
x
Stiffness K
Figure 64: Main Effect Plot for Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section
Stiffness Kx
y
Stiffness K
Figure 65: Main Effect Plot for Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section
Stiffness Ky
z
Stiffness K
Figure 66: Main Effect Plot for Joint 12: Deep Hat Section to Rectangular Tube Section Stiffness Kz
x
Stiffness K
Figure 67: Main Effect Plot for Joint 12: Deep Hat Section to Rectangular Tube Section Stiffness Kx
y
Stiffness K
Figure 68: Main Effect Plot for Joint 12: Deep Hat Section to Rectangular Tube Section Stiffness Ky
z
Stiffness K
Figure 69: Main Effect Plot for Joint 13: Full Height Channel Section to Rectangular Tube Section
Stiffness Kz
x
Stiffness K
Figure 70: Main Effect Plot for Joint 13: Full Height Channel Section to Rectangular Tube Section
Stiffness Kx
y
Stiffness K
Figure 71: Main Effect Plot for Joint 13: Full Height Channel Section to Rectangular Tube Section
Stiffness Ky
z
Stiffness K
Figure 72: Main Effect Plot for Joint 14: Full Height Rectangular Tube Section to Rectangular Tube
Section Stiffness Kz
x
Stiffness K
Figure 73: Main Effect Plot for Joint 14: Full Height Rectangular Tube Section to Rectangular Tube
Section Stiffness Kx
y
Stiffness K
Figure 74: Main Effect Plot for Joint 14: Full Height Rectangular Tube Section to Rectangular Tube
Section Stiffness Ky
z
Stiffness K
Figure 75: Main Effect Plot for Joint 15: Full Height Channel Section to Channel Section Stiffness Kz
x
Stiffness K
Figure 76: Main Effect Plot for Joint 15: Full Height Channel Section to Channel Section Stiffness Kx
y
Stiffness K
Figure 77: Main Effect Plot for Joint 15: Full Height Channel Section to Channel Section Stiffness Ky
Introduction
A design experiment was run using Altair HyperStudy [4]. The experiment considered the linearity of the
joint parameters and the interactions between them on the joint stiffness. The mathematical response of
each joint was programmed into an Excel spreadsheet. Designers and engineers will be able to enter joint
dimensions, thickness, and any discrete variables simulated in the DOE, and obtain calculated joint
stiffnesses. The Excel spreadsheet allows the user to input any joint definition that is within the DOE
experiment range.
The spreadsheets also contain Design Rules and Observations to be considered when making design
decisions. The Design Rules were created from finite element and sensitivity analysis data to help make
stiffer joints. The Joint Observations contained information regarding joint deflection and welding
information stemming from the analytical results.
The spreadsheet for each of the ten joints in Phase 2 of the study is shown in Figure 79 through Figure
98. The spreadsheet for Joint 2A is shown in Appendix D. There are two figures for each joint. The first
figure shows the input and calculated results for the joint stiffness, and the second figure shows the Joint
Observations, Notes and Design Rules.
Figure 78 displays the general bi-linear nature of the stiffness for the two riveted joints. In the figure, it is
shown that the stiffnesses K1 and K2 represent the stiffness of the joint. K1 is the stiffness of the joint
when it is operated beyond the +/- 1000N load and K2 is the stiffness when it is operated within the +/-
1000N load. It is clear from the figure that stiffness K1 will always be greater than K2. We determined
from joint test data that the ratio of the two stiffness was constant:
K1
= constant
K2
In the above equation, the "constant" is derived from the test data and it is specific to each joint. In the
toolbox, the stiffness K1 is calculated using the DOE results. To determine stiffness K2, the following
equation is used.
K1
K2 =
constant
Figure 79: Joint 6 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
actual stiffness
Figure 80: Joint 6 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Figure 81: Joint 7 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
which to input
beyond 1000
Figure 82: Joint 7 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Joint 8
Figure 83: Joint 8 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
in which to input
calculated stiffnesses
Figure 84: Joint 8 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Figure 85: Joint 9 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
in which
stiffnesses will be
a tubular section.
Figure 86: Joint 9 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Joint 10:
Figure 87: Joint 10 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
in which
stiffnesses will be
Figure 88: Joint 10 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Joint 11:
Figure 89: Joint 11 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
Figure 90: Joint 11 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Joint 12:
Figure 91: Joint 12 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
of the joint.
a lot.
Figure 92: Joint 12 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Figure 93: Joint 13 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
Figure 94: Joint 13 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Joint 14:
Figure 95: Joint 14 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
Figure 96: Joint 14 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
Figure 97: Joint 15 Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
Figure 98: Joint 15 Joint Stiffness Toolbox Spreadsheet Joint Observations and Design Rules
1. Lewis, Katy; Spencer, Christian; White, Michael: Light Truck Frame Stiffness Study, Auto/Steel
Partnership, Report No. A/SP-005-1, July 25, 2001.
2. Altair Engineering, Inc.: Joint Stiffness Toolbox, Excel Spreadsheet, Auto/Steel Partnership, July
2001.
3. Spencer, Christian; Vartanian, Katy; White, Michael; Law, S.Edward: Light Truck Frame Joint
Stiffness Study, Society of Automotive Engineers Paper 2002-01-0241.
The following figures are the plots of all the test data for the two joints (Joint 6 and 7).
The figures in this appendix illustrate the joint design variables that were considered for the final DOE
study. These are the same design variables (shape and thickness) that are included in the joint stiffness
toolbox.
Based on the sensitivity information from this screening DOE study, the following parameters were either
eliminated from the screening DOE study or added to the final DOE study.
Joint 2 from Phase 1 was modified and a new version, hereafter referred to as Joint 2A, was developed.
The same DOE analysis was performed on this joint and this appendix documents the results from that
study. Figure 131 displays the original Joint 2 from the Phase 1 study. Figure 132 displays the new
Joint 2A.
Observe from Figure 132 and Figure 136 that the only modification to the new joint consists of the Side
Rail being closed off by Plate B, thereby creating a box section.
Side Rail C
Channel
Crossmember
Indicates Weld
Indicates Weld
Indicates Weld
Figure 136 through Figure 138 display the main effects on stiffness of the various parameters for
Joint 2A.
Figure 139 and Figure 140 display the Toolbox and Design Rules respectively for Joint 2A.
z
Stiffness K
Figure 136: Main Effect Plot for Phase 1 Joint 2A Full Boxed to Lipped Channel Stiffness Kz
x
Stiffness K
Figure 137: Main Effect Plot for Phase 1 Joint 2A Full Boxed to Lipped Channel Stiffness Kx
y
Stiffness K
Figure 138: Main Effect Plot for Phase 1 Joint 2A Full Boxed to Lipped Channel Stiffness Ky
Joint 2A:
Figure 139: Phase 1 Joint 2A Joint Stiffness Toolbox Spreadsheet Input and Calculated Results
Figure 140: Phase 1 Joint 2A Joint Stiffness Toolbox Spreadsheet Joint Observations and
Design Rules
Tension testing was performed on the coupons cut from the joint materials. The tension testing was done
as per the ASTM E8 standard. The results of this testing are presented in the form of Stress versus
Strain curve. Figure 141, Figure 142, Figure 143, Figure 144 and Figure 145 display the Stress versus
Strain data for the coupons cut from Joint 6 crossmember, Joint 6 siderail, Joint 7 crossmember, Joint 7
inner siderail and Joint 7 outer siderail respectively.
Figure 144: Stress versus Strain Curve for Joint 7 Inner Siderail
Figure 145: Stress versus Strain Curve for Joint 7 Outer Siderail
Crossmember
Side Rail
Crossmember
Rivet
Rivet
Rivet
Upper Crossmember
Lower Crossmember
Figure 148: Joint 7: Hat Section (with Bracket) to Twin Channel Sections (view 1)
Rivet
Rivet Inner Side Rail
Rivet
Rivet
Rivet
Rivet Lower Crossmember
Figure 149: Joint 7: Hat Section (with Bracket) to Twin Channel Sections (view 2)
Welding between
Outer and Inner
Side Rails
Welding between
Outer and Inner
Side Rails
Figure 150: Joint 7: Hat Section (with Bracket) to Twin Channel Sections (view 3)
Rectangular
Tube Section
Rectangular
Tube Section
Figure 151: Joint 8: Rectangular Tube Section to Rectangular Tube Section (view 1)
Welding
between Side
Rail and
Crossmember
Rectangular
Tube Section
Rectangular
Tube Section
Figure 152: Joint 8: Rectangular Tube Section to Rectangular Tube Section (view 2)
Welding between
Circular Tube and
Channel Sections
Figure 153: Joint 9: Circular Tube Section through Channel Section (view 1)
Tube Section
Channel
Section
Welding between
Circular Tube and
Channel Sections
Figure 154: Joint 9: Circular Tube Section through Channel Section (view 2)
Rectangular
Tube Section Rectangular
Tube Section
Figure 155: Joint 10: Rectangular Tube Section Through Rectangular Tube Section (view 1)
Rectangular
Tube Section
Rectangular
Tube Section
Figure 156: Joint 10: Rectangular Tube Section Through Rectangular Tube Section (view 2)
Rectangular
Tube Section
Welding between
the two
rectangular
sections
Rectangular
Tube Section
(Angled)
Figure 157: Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section (view 1)
Rectangular
Tube Section
Welding between
Cap and Tube
Section
Cap
Rectangular
Tube Section
(Angled)
Figure 158: Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section (view 2)
Rectangular
Tube Section
Welding between
the two Sections
Rectangular
Tube Section
(Angled)
Figure 159: Joint 11: Rectangular Tube Section (Angled) to Rectangular Tube Section (view 3)
Welding between
the two Sections
Rectangular
Tube Section
Deep Hat
Section
Figure 160: Joint 12: Deep Hat Section to Rectangular Tube Section (view 1)
Rectangular
Tube Section
Deep Hat
Section
Welding between
the two Sections
Figure 161: Joint 12: Deep Hat Section to Rectangular Tube Section (view 2)
Rectangular
Tube Section
Full Height
Channel Section
Welding
between two
sections
Figure 162: Joint 13: Full Height Channel Section to Rectangular Tube Section (view 1)
Full Height
Channel Section
Rectangular
Tube Section
Figure 163: Joint 13: Full Height Channel Section to Rectangular Tube Section (view 2)
Rectangular
Tube Section
Full Height
Rectangular
Tube Section
Welding between
two sections
Figure 164: Joint 14: Full Height Rectangular Tube Section to Rectangular Tube Section (view 1)
Full Height
Rectangular
Rectangular Tube Section
Tube Section
Welding between
two sections
Figure 165: Joint 14: Full Height Rectangular Tube Section to Rectangular Tube Section (view 2)
Channel Section
Full Height
Channel Section
Welding between
two sections
Figure 166: Joint 15: Full Height Channel Section to Channel Section (view 1)
Channel Section
Full Height
Channel Section
Welding between
two sections
Figure 167: Joint 15: Full Height Channel Section to Channel Section (view 2)