International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 08 | Aug 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 752 Failure Analysis of Body Control Module under Mechanical Shock & Random Vibration Loading Mr. Bipin S Dhole 1 , Prof. Shailesh.S.Pimpale 2 , Dr. Subim.N.Khan 3 1 Student(Mechanical Engg. Dept.) JSPM’SRajarshi Shahu College of Engineering Pune 2 Professor(Mechanical Engg. Dept.) JSPM’S Rajarshi Shahu College of Engineering Pune 3 Doctor (Mechanical Engg. Dept.) JSPM’S Rajarshi Shahu College of Engineering Pune ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - The Body Control Module design is used for off highway vehicle .In new product development cost and time is very important. Simulations technique is playing important role with testing when concept of new design BCM considered for off highway vehicle, design should stand under high vibration and structural loading Key Words: Body Control Module, Mechanical Shock, Bolt Torque, Engine RPM 1. Introduction The Body Control Module regulates the operation and coordination between the different parts of the car also by using signals of some sort. The various electronic parts of the vehicle are actually controlled by a Body Control Module – from the car light to the simple door locks; each part has a module that controls it. In today’s automotive setups, these modules are operating under a single assembly – they are now controlled by the Body Control Module. It may seem like the module performs a very complex function. Hence this Body Control Module has been protected from the damage during handling and vehicle running condition. This Body Control Module is subjected to various loading conditions such as vibration loading, Impact loading, mechanical shock. One of the case studies is doing to modify the existing Body Control Module. These modifications are carried out by using Computer Aided Engineering approach and verified by the experimental results. The software being used for the simulation is ANSYS and Ls-DYNA/explicit method 2. LITERATURE REVIEW Mechanical Shock Condition: Seungbae Park, Chirag Shah, Jae Kwak, Changsoo Jang and James Pitarresi studied “Transient dynamic simulation and full-field test validation for a slim-PCB of mobile phone under Drop / Impact”. This paper gives description about a numerical model for a drop test has been developed using ANSYS / LS-DYNA that addresses the limitations of traditional time consuming methodologies. To eliminate strike surface uncertainties, the known input pulse measured on the test vehicle is supplied as base acceleration to the entire model. For that, a shaker table has given half-sine impact acceleration. On that shaker table test board is placed and test is carried out. In this, using acceleration as an input the drop test is carried out and the highest stress and most susceptible failure zone is found out. The numerical model has been validated against experimental measurements of acceleration, velocity (derived) and strain, the results show an excellent correlation with all measured data. Bolting Joints: Mike Guo and Shujath Ali studied “Study on Simplified Finite Element Simulation Approaches of Fastened Joints”. Source: SAE 2006-01-2626. In this paper, mechanism of fastened joints is described; numerical analyses and testing calibrations are conducted for the possible simplified finite element simulation approaches of the joints; and the best simplified approach is recommended. The approaches cover variations of element types and different ways that the joints are connected. The element types include rigid elements, deformable bar elements, solid elements, shell elements and combinations of these element types. The critical fatigue damage area is located at a bolt joint on the rear bumper beam bracket. Jeong Kim, Joo-Cheol Yoon, Beom-Soo Kang studied “Finite element analysis and modeling of structure with bolted joints”. Source: Science Direct 2006. This paper gives information about the bolt model adopted for a structural analysis of a large marine diesel engine consisting of several parts which are connected by long stay bolts. In order to investigate a modeling technique of the structure with bolted joints, four kinds of finite element models are introduced; a solid bolt model, a coupled bolt model, a spider bolt model, and a no-bolt model. All the proposed models take into account pretension effect and contact behavior between flanges to be joined. Among these models, the solid bolt model, which is modeled by using 3D solid elements and surface-to-surface contact elements between head/nut and the flange interfaces, provides the best accurate responses compared with the experimental results. In addition, the coupled bolt model, which couples degree of freedom between the head/nut and the flange, shows the best effectiveness and usefulness in view of computational time and memory usage. Hsiu-Ying Hwang studied “Bolted joint torque setting using numerical simulation and experiments”. Source: Journal of Mechanical Science and Technology (Springer) 2012. This paper gives description about a numerical simulation using the finite element method to determine the