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Objectives
Describe the chassis frame of a heavy-duty
truck.
Define the terms yield strength, section
modulus (SM), and resist bend moment (RBM).
List the materials from which frame rails are
made and describe the characteristics of each.
Explain the elements of frame construction.
(Objectives cont.)
Explain how the chassis frame, side rails, and
cross-members can be repaired without
altering the frame dynamics.
Perform some basic chassis frame alignment
checks and project a frame-to-floor diagram.
Describe the various categories of frame
damage, including diamond, twist, sidesway,
sag, and bow.
INTRODUCTION
The chassis frame is the backbone of all
heavy-duty vehicles. The main body of the
frame on a highway tractor is shaped like a
ladder. In fact, we commonly refer to a heavyduty truck frame as a ladder frame.
Drop Style
Straight Type
FRAME DESIGNS
C-channel rail section
Bending Moment
The higher the SM, the less flexible the frame tends to be.
Yield Strength
Yield strength is a measure of the material
strength of the frame. By definition, yield
strength is the maximum stress that a
material can withstand before it is
permanently deformed. Yield strength is
factored with SM to calculate RBM. On road
generally uses -inch steel whereas on/off
road uses 5/16 or 3/8 steel.
Shop Talk
Two truck frames with identical RBM can
perform very differently. RBM is calculated by
factoring SM with yield strength. If two trucks
have identical RBM but one is specd with a
high SM but uses a lower yield strength
material, it will be more rigid than a frame
with high yield strength but low SM.
Steel Frames
Trucks are manufactured with frame rails of
mild steel (36,000 psi yield strength), highstrength low-alloy (HSLA) steel (50,000 psi
yield strength), or heat-treated steel (110,000
psi yield strength). On the inside of the frame
rail there should be stencil data that tells how
the frame is constructed. Most frames cannot
be welded or drilled.
FRAME LOADING
CROSS-MEMBERS
Cross-members are designed to connect the
frame rails. They provide rigidity and strength,
along with sufficient flexibility to withstand the
twisting and bending stresses encountered
when operating on uneven terrain. Stamped
C-section is a standard type of crossmember.
CAUTION:
When reassembling chassis components
previously assembled with Huck fasteners, it
is often unrealistic to install new Huck
fasteners because of accessibility. If you are
replacing Huck fasteners with bolts, ensure
that their hardness is consistent with the
original fasteners. This will usually, but not
always, be equivalent to an SAE Grade 8
fastener.
FRAME CONSTRUCTION
Frames may be single, double, or triple
construction. Additionally, most frames are
available with either inside or partial inside
channel reinforcements or outside
reinforcements. The reinforcements are used
to provide a greater RBM and SM over a
section of the frame.
MULTIELEMENT RAILS
Reinforcements
DRILLING
Careful consideration should be given to the
number, location, and sizes of frame bolt
holes in the design of a vehicle. The number,
location, and sizes of additional bolt holes
installed to the frame subsequent to
manufacture of the vehicle can adversely
affect frame strength.
Drilling Method
Shop Talk
When any type of frame reinforcement is
added, straight cut fishplates, L-sections, and
C-channels should be avoided because this
creates a sudden increase in SM. This
sudden increase in SM can cause frame
failures immediately adjacent to the
reinforced section.
STRESS CONCENTRATORS
In any modification of the chassis frame, the
addition of holes, reinforcements, welds,
clamps, splices, and so on, may cause an
increase in local stress in the frame at the
point of the modification. These local stress
concentrations can significantly affect the life
of the chassis frame.
CORROSION
Frame damage also may be caused by
corrosion caused by the contact between
dissimilar metals. If aluminum and steel, for
example, are allowed to come into direct
contact, galvanic corrosion can eat away both
materials. Aluminum is anodic with respect to
steel and will corrode in its presence.
Shop Talk
Frame straightening should be performed
only by a qualified frame alignment facility.
Because impact-damaged frames are
repaired by specialty technicians using
specialty equipment, this type of frame
servicing is not covered in this book.
FRAME ALIGNMENT
Tire inflation.
Front end alignment.
No visual frame damage or bent axle housings.
Proper wheel and tire balance.
Tires and rims must be of the proper size and type
with no mismatching.
On disc wheel assemblies, the wheel discs should
be the same on all wheels.
Move the vehicle to a level floor, neutralize the
suspension (see Chapter 26), and ensure that the
front wheels are tracked as straight as possible.
FRAME LAYOUT
Welding Procedure
Welds on truck frames are common practice,
but they should be performed by a skilled
welder with some knowledge of how the
repair will affect the frame performance. The
heat-tempered frame rails used on most
highway tractors may be both repair-welded
and extended successfully, providing the
correct methods are used. Use a lowhydrogen welding electrode with a wire
tensile strength rating similar to the frame
rating. (E-11018 is ideal)
Grinding a V-groove
Summary
The chassis frame is the backbone of all
heavy duty trucks.
A truck frame is a dynamic component. It is
designed to flex when subjected to vehicle
loading and road forces. The extent to which
it can flex defines the type of operation that
the truck is suited to.
Summary (cont.)
The frame supports the cab, hood, and
powertrain components, along with the body
and payload.
The two main components of a ladder-type
frame are the two longitudinal members,
which are generally referred to as rails.
Ultimate frame strength is measured for
comparative purposes by resist bend moment
(RBM).
Summary (cont.)
RBM is factored by section modulus and yield
strength.
Section modulus (SM) concerns the shape of
frame beams. High SM produces a more rigid
frame. Low SM produces higher flexibility.
Hardened steel frame rails are formed from
high-strength alloy steel, quenched and
tempered (heat-treated) to a minimum yield
strength of 110,000 psi.
Summary (cont.)
A bent frame can decrease the control a
driver has over a vehicle during an
emergency and increase the chances of an
accident occurring.
Frame damage can be generally categorized
as diamond, twist, sideway, sag, and bow.