Improved Performance of Box Truck Life using Computational Analysis

Abstract

This case study presents an investigation of the structural behavior of a box truck body mounted on the chassis of a Volkswagen Constellation 24.330, utilizing Finite Element Method (FEM). The study specifically evaluates the performance of the structure under static and fatigue conditions, comparing scenarios with and without reinforcement applied to the rear column. Aimed at improving the structural performance and durability of commercial vehicles, the research focuses on identifying stress distribution, analyzing torsional behavior, and addressing common structural failures such as cracks and deformations. The results demonstrate that the implementation of rear column reinforcement enhances the structural performance of the box body. Stress concentrations were reduced by over 30% under uniform load conditions, while maximum displacement under torsion decreased by 64%. Additionally, the torsional stiffness of the structure increased by 162%, leading to improved durability and greater resistance to dynamic loads. The fatigue analysis showed infinite life for most parts of the reinforced structure; however, critical areas, such as the intermediate columns and lower I-beam regions, were identified as stress concentration zones requiring closer attention to manufacturing quality. This study highlights the importance of computational simulations in optimizing vehicle design by enabling accurate predictions of structural behavior. By reducing stress concentrations and improving durability, the proposed solution addresses the challenges faced by commercial vehicles and enhances their safety and reliability in the market.