31/07/26 Fri 15:38pm
Continuing from…
Application Based Questions
3. Battery Mounting Bolt
The Scenario
“After driving over potholes, the batter pack becomes loose. Inspection shows two mounting bolts fractured.”
Why?
- Wrong bolt diameter?
- Wrong preload?
- Dynamic loading?
FEA → Represent bolt as Bar element
Find - Tensile stress
- Elongation
- Safe diameter
4. Suspension Tie Rod
The Scenario
“Vehicle hits a speed bump / breaker. Tie rod bends.
Steering alignment changes. Vehicle pulls left.”
This is because of What?
- Diameter increase?
- Material change?
- Hollow Tube?
- Solid rod?
5. Battery Cooling Pipe Expansion
The Scenario
“Battery Temperature reaches 65. Cooling pipe expands. Supports prevent expansion. Pipe buckles.
Should we
- Increase clearance?
- Change material?
- Add expansion loop?
1D Analysis → use Thermal Bar Element to find - Thermal stress
- Thermal expansion
6. Charging Cable Stretch
The Scenario
“The fast charger cable becomes longer after repeated use.
Connector alignment changes.”
Is it
- Plastic deformation?
- Elastic deformation?
- Material issue?
FEA
Cable
1D tension element
Calculate
Stress
Elongation
7.Motor Mount Bolt
The Scenario
Customer Reports vibration, Inspection finds: motor mount bolt loosened.
Why?
- Bolt too small?
- Improper preload?
- Material Fatigue?
1D Bar Element Calculate
- Bolt stress
- Elongation
- Preload
8. Suspension Spring
The Scenario
“Battery weight increased by 80 kg.
Ride height drops.
Should we
- Increase wire diameter?
- Increase spring stiffness?
- Use a different material?
1D Spring Element Calculate - Spring stifness
- Deflection
| S.No. | Real Component | 1D Element | Engineering Concept |
|---|---|---|---|
| 1 | Battery Lifting rod | Bar | Axial tension |
| 2 | Battery mounting bolt | Bar | Axial stress & deformation |
| 3 | Steering tie rod | Bar | Combined loading discussion |
| 4 | Motor shaft | Shaft | Bending |
| 5 | Chassis cross member | Beam | Bending |
| 6 | Suspension spring | Spring | Stiffness & deflection |
| 7 | Battery cooling pipe | Thermal bar | Thermal expansion |
| 8 | Charging cable | Cable | Tensile elongation |
Overview of CAE
- Use of computer software to assist engineering analysis.
- Encompasses simulation, validation, and optimization of products.
- CAE helps to solve complex engineering problems quickly.
- Reduces prototyping costs, improves design efficiency, and accelerates development timelines.
- CAE tools are essential for modern engineering, offering accuracy, efficiency, and innovation.
CAE Workflow Overview:
- Concept design: Using CAD tools to create a rough design representation.
- Model Creation: Assigning material & boundary conditions to the 3D model imported from CAD software.
⬆ midterm question!!!!!
