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Linear static analysis of heavy commercial truck chassis assembly has become an industry practice during the concept stage evaluation. Non-linear analysis of chassis is rarely performed due to computational time and resource constraints. However, linear assumptions might not be appropriate for certain regions in the chassis assembly. In this paper, sub-modeling technique is applied for solving specific regions in the full chassis assembly to capture the actual boundary information for local non-linear analysis without intervention of user.

Truck chassis assembly forms the structural backbone of a heavy commercial vehicle. The main function of the truck chassis is to support the aggregate components and payload acting on it during operating conditions. The chassis is subjected to vertical loading (Bump), fore and aft loading (braking and acceleration), lateral loading (Cornering) and torsional loading (Articulation). Out of the above load cases, the vertical load (bump load) decides the maximum load carrying capacity of the chassis when the vehicle traverses uneven surfaces. This paper explains the importance of theoretical bending stress calculation of truck frame side member (FSM) subjected to vertical load which will help the designer to arrive at the major section of FSM during initial stage of the design. Different concept proposals of FSM can be evaluated using these calculations quickly.