Design and analysis of turbo charger

ABSTRACT

In these days of technological advancements in Automobile sector where mans penchant is to develop technologies that can improve the power and mileage of the vehicle TURBOCHARGER is one such exotic gadget.

Any engine needs air for combustion of fuel and it is the Air-Fuel ratio the decides the performance of an engine. Hence supply of air is an important task. During high speed operation of any engine there is not enough time for air to be sucked in the cylinder by itself (by the creation of vacuum during suction stroke).Hence the volumetric efficiency goes on decreasing as engine picks up speed as a result of which only partial combustion takes place. To fulfill the deficiency of air supercharging and consequently turbocharging came into picture.

A TURBO CHARGER is basically an exhaust gas driven air compressor which compresses the ambient air and sent this pre compressed (optionally Intercooled) air into the cylinder during suction stroke. It consists of two basic parts, the exhaust gas driven turbine and its housing, and the air compressor and its housing. The exhaust air from the engine spins the turbine and leaves while the compressor wheel, connected to the common shaft of turbine and compressor, compresses the ambient air and feeds it to the engine.

Modern turbochargers are complex assemblies of various accessories attached to it like wastegate, blow off valves, oil and water plumbing, ECU with sensors, Pressure gauges etc.

Since the turbine spins at exceptionally very high speeds of the order of 1-2 Lac rotations per minute it has to designed carefully taking various parameters into considerations. Also as it is continuously subjected to very high exhaust gas temperature of the order of 600-900 degree centigrade thermal strength also plays important role. Turbine of the turbocharger also has to resist the high pressure of the exhaust gas at elevated temperatures.

Hence in our project we have incorporated the two major design considerations of turbine of Turbocharger:

Structural Aspects.

Thermal Aspects.

Modeling and Analysis of the turbine wheel of a turbocharger is presented in our project. For modeling we have used the real time modeling package ProEngineer WF 3.0 and for analysis we have used the prevalent FEM analysis package ANSYS 10.

Our Analysis includes both Structural and Thermal Analysis of the turbine wheel.

Special focus on the results part has been given in order to help designers. Various contour plots has been studied and presented so as to acquire proper idea about the deflections and stress distributions on the turbine blade.

In case of thermal Analysis, Nodal temperatures and the distribution of the temperature across the turbine blade has been obtained and explained.

Another interesting part of our project is the “EXTENSION OF TURBOCHARGING TO TWO WHEELERS”

We have presented the possibilities of turbocharging a two wheeler which has not been done yet in commercial vehicles till date.

Turbocharging a two wheeler has many potential like power boost, Mileage improvement etc which can be achieved easily by installing a turbocharger.

We have presented the advantages and limitations of this concept.

Tittle: Design and buckling analysis of two post Screw auto lifter.

ABSTRACT:

A good automobile shop must have equipment to undertake all types of fault finding and servicing jobs.

The tools and equipment which are must in the auto shop are namely screw drivers, spanners, hydraulic

lift, wheel balancing equipment etc. One of the important equipments is the hydraulic lift which can be a

2-post, 4-post, 6-post which is used to lift the vehicles to a comfortable height in order to work under it.

For the same purpose the latest equipment used is the Screw Auto Lift.

Much of the fatigue damage in the tools and equipments of a auto shop can be limited to the

compressive forces acting on them. Buckling under axial load is one of the most common failures which

appear before crushing. This project is about “Buckling Analysis on a two post Screw auto lift”. The

compression members, whom we come across, do not fail entirely by crushing. These members, which

are considerably long when compared with their lateral dimensions start bending, i.e. buckling. When

the axial load reaches a certain critical value, and screw auto lift is one such member. Both experimental

and analytical work has been performed on a screw auto lift; employing commercial ansys program,

based on the finite element method on a 3d solid model developed in pro/e.

The possible use of alloy steels(nickel steels) in place of mild steel has got improved properties like

increase in the strength and the elastic limit of the alloy .The results suggest that use of the nickel steels

improves the properties such as strength, ductility, and corrosion resistance over the specifications of

the two post screw auto lift. .It also increases the durability of the equipment, two post screw auto lift.

Project 2:

Tittle : Design and analysis of spindle with Spm (special purpose machine).

ABSTRACT

The present work is carried out on TWO STATION TWO SPINDLE CAM BORE ROUGHING /FINISHING

SPM.It is a SPECIAL PURPOSE MACHINE exclusively used for HEROHONDA in which it is used for fine

boring to reduce the oil consumption of the two wheeler.

The objective of my project is to generate a parametric assembly drawing of spindle assembly

using Pro-E, and analysis of spindle assembly using ANSYS.

Firstly, we created a solid model of the crankshaft using designing software

“Pro-e”. Then the model is imported into Ansys and analyzed by applying necessary conditions, which

were considered in designing it and then checked for the strength and life. The specifications required

for the design are taken from the drafted design

The analysis of spindle assembly includes:

Analysis of spindle deflection due to tensioning of belt

Spindle analysis for deflection due to axial and radial forces

Based on deflection decide an optimum positioning of the spindle bearings

. Project 3:

Tittle: Structural analysis of six wheeler chassis.

ABSTRACT

The present scenario in automotive industry is an increase in demand of trucks not only on the cost and weight aspects but also on improved complete vehicle features and overall work performance. The chassis plays an important role in the design of any truck.

The chassis design in general is a complex methodology and to arrive at a solution which yields a good performance is a tedious task. Since the chassis has a complex geometry and loading patterns, there is no well defined analytical procedure to analyze the chassis. So the numerical method of analysis is adopted, in which ‘Finite Element Technique’ is most widely used method.

The main objective of this work is to evaluate static characteristics of a truck chassis under different load conditions. Geometric modeling of the various components of chassis has been carried out in part mode as 3-D models using PRO-ENGINEER. The properties, viz. crossectional area, beam height, area moments of inertia of these 3-D modeled parts are estimated in PRO-ENGINEER. These properties have been used as input while performing the Finite Element Analysis using ANSYS work bench.

Project 4:

Tittle: Design and analysis of connecting rod 4s S.I engine.

ABSTRACT

Connecting rod is a structural member in the engine, which transfers reciprocating motion into

rotary motion of crank shaft

The connecting rod while transferring the power from piston to crank shaft takes load from piston due

to combustion process in the combustion chamber

The load acts at a particular crank angle to the max hence the connecting rod is analyzed due to stress

developed, due to load conditions and changes mentioned

In this analysis a model of connecting rod is generated in pro/e and analyzed in ansys using FEM (finite

element method) by applying loads and boundary conditions, and then solved for engineering

responses.

Project 5:

Tittle: Design and analysis of crank shaft 4s S.I engine.

ABSTRACT

In this project we designed and analyzed a crankshaft of 4-stroke S.I engine using “Ansys”, which is

software, which works on the basis of finite element method.

Firstly, we created a solid model of the crankshaft using designing software “PRO/E”. Then the

model is imported into Ansys and analyzed by applying necessary conditions, which were considered in

designing it and then checked for the strength and life. The specifications required for the design are

taken from the drafted design.

The results were found in the analysis of the crankshaft, the design is found out to produce more

stresses and some modifications were done to the design and again it is analyzed and the stresses

developed were lesser when compared to the previous design.

The engine, which is used, is a four-stroke S.I engine. It is a twin cylinder multi utility engine. It is

a horizontal shaft engine. The cylinder volume of the engine is 196cc and it is used in cold countries for

snow cutting purpose. It is also used for grass cutting.

Project 6:

Tittle: Structural and thermal analysis of gas turbine casing

ABSTRACT

Gas Turbine is a rotary engine, which converts the energy of hot gases into mechanical energy.

The hot flue gasses at high pressure and high temperature expand in the turbine section to

produce mechanical work. Turbine casing (shell) controls the axial and radial positions of

the shrouds and nozzles.

It determines Turbine clearances and relative positions of the nozzles to the Turbine buckets.

This positioning is critical to Gas Turbine performance.

The main objective of the present investigation is to analyze the temperature distribution,

stresses developed throughout the casing by using FEM. In this project thermal analysis

at steady state, thermal and structural analysis and optimization of casing are carried out.

Thermal and structural analysis on casing is carried out with increased gas temperatures

than the existing operating conditions.

Project 7:

Tittle: Design and analysis of piston 4s S.I engine.

ABSTRACT

The project “DESIGN AND ANALYSIS OF 4-STROKE S.I. ENGINE PISTON” is about designing the

piston according to the forces acting on it from the gases, which are released during the combustion.

The piston head acts as a particular case and hence the piston is analyzed for the stresses developed due

to the conditions.

At first, the piston is designed according to the specifications. After the designing, the model is subjected

to certain conditions. According to the conditions we have checked the stresses acting on it and checked

the failures of the model. After the analyzing the changes are done to the model if required.

In the analysis a model of piston is generated using Pro/E. the finite element model of the piston is

generated using Ansys. It is applied with loads and boundary conditions. Thus solved for the engine

response.

The result are calculated and tabulated below and the stresses acting on the body are shown.

Project 8:

Tittle: OPTIMIZATION & ANALYSIS OF RICE MILL ROLLER.

ABSTRACT

The rollers used in rice mill are also called as friction rollers. The use of these rollers is to remove the husk from the rice. In practice, there will be two rollers which rotate in opposite direction. The paddy flows between these rollers and separates the husk and rice. During this separation a high amount of the friction is induced in these rollers. Due to this friction the rollers have a chance of breakage at exactly the center of the roller. The maximum life of these rollers is not more than two to seven days.

The present work is carried out to overcome these problems. We approach the problems in two ways to increase the life of the rollers and strength of the rollers. Since these rollers have a circular cross section and more number of boundary conditions, which analytical methods fail to analyze. Hence, we employed numerical methods which provide an approximate, but acceptable solution. Finite Element Method technique is applied for boundary value problems and it is integrated with high speed digital computer and to analyze complex domain with relative ease.

For this analysis component is modeled in PRO/E, which is then imported to HYPERMESH for attaining the pre- processing and then it is exported to ANSYS for analyzing structural, linear and rotational stress analysis.

Project 9:

Tittle: ACTIVE TWIST OF MODEL ROTAR BLADES WITH D-SPAR DESIGN.

ABSTRACT

The design methodology based on the planning of experiments and response surface technique has been developed for an optimum placement of macro fiber composite (MFC) actuators in the helicopter rotor blades. The baseline helicopter rotor blade consist of D-spar made of UD GFRP, skin made of +45/-45 GFRP, foam core, MFC actuators placement on the skin and balance weight. 3D finite element model of the rotor blade has been built by ANSYS, where the blade skin and spar “moustaches” are modeled by the linear layered structural shell elements SHELL63, and the spar and foam –by 3D 20-node structural solid elements SOLID 45. The thermal analyses of 3D finite element model have been developed to investigate an active twist of the helicopter rotor blade. Strain analogy between piezoelectric strains and thermally induced strains and thermally induced strains is used to model piezoelectric effects. The optimization results have been obtained for design solutions, connected with the application of active materials, and checked by the finite element calculations.

Project10.

Tittle: DESIGN AND ANALYSIS OF A COMPOSITE BEAM FOR SIDE IMPACT PROTECTION OF A SEDAN .

ABSTRACT

Side Impact crashes can be generally dangerous because there is no room for large deformation to protect an occupant from the crash forces. The side impact collision is the second largest cause of death in United States after frontal crash. Day by day increase in the fuel cost and the emission of the smoke from the automobile industry are also the major concerns in the contemporary world, hence the safety, fuel efficiency and emission gas regulation of the passenger cars are important issues in contemporary world. The best way to increase the fuel efficiency without sacrificing the safety is to employ composite materials in the body of the cars because the composite materials have higher specific strength than those of steel. Increase in the usage of composite material directly influences the decrease in the total weight of car and gas emission. In this research, Carbon/Epoxy AS4/3051 -6 is used as material for side impact beam which has adequate load carrying capacities and that it absorbs more strain energy than steel.

The Finite Element models of a Ford Taurus car and the Moving Deformable barrier (MDB) as developed by National Crash Analysis Center (NCAC) have been utilized for the analysis in this thesis. The current side impact beam is removed from the car and the new beam which is developed using CATIA and MSC.Patran is merged on to the driver side of the front door of the car model.

The total energy absorption of the new beam with steel and composite material is compared with the current beam. The intrusion of the beam is evaluated by using FMVSS 214 and IIHS side impact safety methods. The new impact beam with composite has high impact energy absorption capability when compared to current beam and new beam with steel, with 65% reduction in weight.

Project 11.

Tittle: An Experimental Study on the Vibration Characteristics of the Rotor Blade with Fiber Reinforced Plastics .

ABSTRACT:

With the current background of increasing oil price, a number of researches on development and supply of renewable energy are on process. Wind energy is one of them. Not only as energy itself, but also as travel resources, windenergy is ideal substitute for Korea equipped with appropriate conditions. The purpose of this paper is that investigates the dynamic behavior characteristic of W.T.S (Wind Turbine System) andcarries out the evaluation analysis during operating W.T.S. To investigate the dynamic behavior characteristic of W.T.S,the experiments to measure vibration of the blade from the attached accelerometer on the flap and edge section of the bladethat is one of the most important elements of dynamic characteristic of W.T.S are performed. Natural frequency and modeshape are calculated with commercial program (ANSYS) using the measured vibration acceleration that receives the signalwith F.F.T Analyzer from the accelerometer. For validation of these experiments, the finite element analysis is performedwith commercial F.E.M program (ANSYS) on thebasis of the natural frequency and mode shape. The results indicate thatexperimental values have good agreements with the finite element analysis. Tittle: STRESS ANALYSIS OF AIRCRAFT METAL FUEL TANK UNDER FEDERAL AVIATION REGULATIONS –PART 23”

ABSTRACT

NAL is in the process of developing HANSA – 4 Aircraft, which is ideally suited for civil transport, aerial survey, training etc. This HANSA is designed according to Federal Aviation Regulations Part 23 (FAR-23) design document. This is a guideline for design of aircraft having a maximum takeoff weight of more than 750 kg and up to 19500 kg. The FAR-23 design document details out the loads and broad procedures for design of aircraft components like fuel tank etc.

The fuel tank designed for HANSA – 4 is made of Aluminum alloy and it can carry 100 liters of Aviation petrol having specific gravity of 0.73. In this work, stress analysis of this fuel tank under FAR loads is considered for different inertia load cases, in addition to static test pressure of 3.5 psi. (24 KPa).

Finite Element Analysis is carried out to arrive at stresses and displacements in critical components. The Analysis is carried out using ansys software finally, from the results it is concluded that the structure is safe and has adequate margin of safety in critical components of fuel tank.

  Project 15

Tittle: MODELING AND ANALYSIS OF MOUNTING PLATE OF A ROTARY COMPRESSOR

ABSTRACT

In the Tecumseh Compressors, the compressors manufactured are using mounting plates having the pitch circle diameter of 211mm. This mounting plate is welded to the compressor bottom and through the holes of this plate; the compressor gets mounted on to the A/C housing.

The vibrations from the compressor get transferred to the A/C housing there by producing noise, which is undesirable. These vibrations will be greater enough to produce noise when the natural frequencies of the compressor, the mounting plate and the A/C housing coincide resulting in resonance. To avoid this, there should be a frequency shift in either of the components. Frequency shift in Mounting Plate will give better results as that is the media of transfer of Vibrations form compressor to the A/C housing.

Under this Project, determination of the Natural frequencies of the mounting plate, amplitudes of vibration in it are studied. This determination is done using Static, Modal and Harmonic Analyses. Three models have been considered and on the existing model experiments have been carried out. The analysis results of the existing model are compared with the experimental results and validating the analysis procedure, the same analyses are carried out to the rest of the two models. Upon analysis of the three models, the better one out of them is suggested.

  Project 16

Tittle: DESIGN AND ANALYSIS OF INJECTION MOULD FOR MINERAL WATER BOTTLE CAP

ABSTRACT

Injection molding is the most important process in the manufacturing of plastic parts. It is done by forcing melted plastic in to a mold cavity until it cools and forms a specific plastic shape. Plastic injection molding is very useful when the plastic parts that need to be produced are too complex or

expensive to do by machine. With plastic injection molding, many parts can be made simultaneously (using the same mold).

The plastics used are the thermo-plastic (hdpe) as these materials soften when heated and re-harden when cooled. No chemical changes take place when the material is heated or cooled, the change being entirely physical. For this reason, the softening and re-hardening cycle can be repeated any number of times.

In this work, stress analysis of this cap cavity plate under the pressure 40 N/mm2 is considered, in addition to this thermal analysis is carried out at injection temperature 2200C and mold temperature 200C.

Cap is modeled in PRO-E and the meshing part is done in HYPER MESH 7.0 and analysis is carried out in ANYSIS 10.0. A finite element analysis is carried out to arrive at stresses, and deformation in cap cavity plate. Finally, from the results it is concluded that the structure is safe and has adequate safety in component of cap assembly.

  Project 17

Tittle: DESIGN AND ANALYSIS OF AUTOMOTIVE TRUCK CAB SUSPENSION SYSTEM

ABSTRACT

The suspension system is used to isolate the chassis from the shock loads due to irregularities of the road surface. This must be handled without impairing the stability, steering or general handling of the vehicle. Suspension system for the cab is placed between the bottom of the truck cabin floor and chassis. The suspension system is fitted to the chassis using bolts. The loads coming from the floor and the chassis are taken by the suspension system to reduce the shocks levels to the driver in the cabin.

The model is designed in Catia V5 and meshed in Hypermesh7.0 and translated to Ansys 10.0. The model is simplified in Ansys by using the preprocessor. Constraint equations and couples are used to connect various regions of the suspension system. The loads are applied on the top flange of the suspension system.

Static analysis is made to study the deflection of the suspension system. Modal analysis is made to check the natural frequencies. Harmonic analysis is also done to plot various graphs between frequency and amplitude. Results and discussions are made from the results obtained from the Ansys and conclusions are given and scope for future work is also given.

  Project 18

Tittle: DESIGN AND ANALYSIS OF TILTABLE TRUCK CABIN FLOOR

ABSTRACT

In the truck the floor as a load gatherer and takes the loads of the driver and co-driver loads and also the side loads and the road loads under different loading conditions. The loads from the road are transmitted to the floor through the vehicle suspension to the cabin suspension and the n to the floor

Floor is modeled in CATIA and the meshing part is done in HYPER MESH 7.0 and analysis is carried out in ANYSIS 10.0. A finite element analysis is carried out to arrive at stresses and deformation on the floor. Finally, from the results it is concluded that the structure is safe and has adequate safety.

  Project 19

Tittle: ANALYSIS OF RESIDUAL STRESSES IN A BUTT WELD USING ANSYS SOFTWARE

ABSTRACT

Low carbon steels are prone to distortion and cracks due to residual stresses induced during welding. This project gives the information about the residual stresses induced in a butt weld joint due

to welding. Experimentation was carried out on a plate made of low carbon steel having dimensions 0.115 x 0.048 x 0.006 meters. The type of welding chosen is Manual Metal Arc Welding (MMAW). Single pass welding was carried out. Experimental values calculated were taken as input for the analysis in ANSYS software.

A model was generated in ANSYS 9.0 (A general purpose FEA software) using SOLID BRICK 8 NODE 70 (3D solid element with temperature dof) and PLANE 55 (A 2D Solid Element with 4 nodes), as per the dimensions of the plate taken for the experimentation. A refined mesh is made based on the convergence criteria and the analysis is performed to estimate the temperature distribution. Firstly a transient thermal analysis was carried out by giving heat flux as the time varying input to estimate the temperature variation. The non-linear material properties are fed for the heat transfer solution. Then coupled field analysis is carried out to get the residual stresses by coupling thermal analysis to static analysis. The variation of the temperature with time, and residual stresses are obtained. The variation of these are reported and discussed.

  Project 20

Tittle: DELAMINATION STUDIES IN FRP COMPOSITES USING 3D FINITE ELEMENT ANALYSIS

ABSTRACT

FRP laminated composites have been extensively used in Aerospace and allied industries due to their inherent advantages over conventional materials. However these are also susceptible to damages especially under transverse loading. Failure modes of such laminated structures are different than those of conventional metallic materials. One important and unique mode of failure in such components is Delamination. Delamination is separation of adjacent plies/laminae due to existence of interlaminar stresses. This mainly occurs at free edges or around discontinuities depending upon the stacking sequence of the laminate. Once Delamination occurs, it becomes important to know whether the laminate could still be used with the existing delamination or up to what size of the Delamination the laminate could be used. So the present work aims at analyzing a laminate having Delamination to determine the severity of the existing Delamination and the propensity of the Delamination growth. 3DFE analysis along with concept of LEFM will be used the FRP laminated composites.

  Project 21

Tittle: DESIGN AND STRUCTURAL ANALYSIS OF HIGH SPEED HELICAL GEAR USING ANSYS

ABSTRACT

Marine engines are among heavy-duty machineries, which need to be taken care of in the best way during prototype development stages. These engines are operated at very high speeds which induce large stresses and deflections in the gears as well as in other rotating components. For the safe functioning of the engine, these stresses and deflections have to be minimized.

In this project, static-structural analysis on a high speed helical gear used in marine engines, have been performed. The dimensions of the model have been arrived at by theoretical methods. The stresses generated and the deflections of the tooth have been analyzed for different materials. Finally the results obtained by theoretical analysis and Finite Element Analysis are compared to check the correctness. A conclusion has been arrived on the material which is best suited for the marine engines based on the results.

  Project 22

Tittle: DYNAMIC ANALYSIS OF THIN –WALLED COMPOSITE I- BEAMS

ABSTRACT

In an effort to save weight while still remaining high strength, many contemporary structural systems are designed with lower margins of safety than predecessors. The criterion of minimum weight design is particularly prevalent in the design of aircraft, missile, and spacecraft vehicles. One obvious means of obtaining a high strength, minimum weight design is the use of light, thin-walled structural members of high strength alloys. Thin- walled beams of open sections such as I, Z, Channel and angle sections are frequently used for intricate structures in spacecrafts. Due to low torsional rigidity thin-walled beams of open sections, the problem of torsional vibrations and stability is of prime interest. For the last three to four decades mechanical vibrations have been recognized as a major factor in the design. Mechanical vibrations produce increased stress, energy loss and noise that should be considered in the design stages if these undesirable effects are to be avoided, or to be kept minimum.

The present work particularly deals with dynamic analysis of lengthy uniform thin-walled uniform I-beams and tapered I-beams of open sections, particularly composite beams. Fiber-reinforced

plastics (FRP) have been increasingly used over the past few decades in a variety of structures that require high ratio of stiffness and strength to weight. In the present thesis, the analytical model developed by Lee and Kim [11] is taken and the dynamic behavior of a thin-walled I-section composite beam is studied in detail. This model accounts for the coupling of flexural and torsional modes for arbitrary laminate stacking sequence configuration, i.e. symmetric as well as unsymmetric, and various boundary conditions are also discussed in detail. A displacement-based one-dimensional finite element model is developed to predict natural frequencies and corresponding vibration modes for a thin-walled composite beam. Equations of motion are derived from Hamilton's principle. Numerical results are obtained for thin-walled composite beams addressing the effects of fiber angle, modulus ratio, height-to-thickness ratio, and boundary conditions on the vibration frequencies and mode shapes of the composites. Using ANSYS 10.0, the modal and harmonic analysis are carried out and presented in graphical form.

  Project 23

Tittle: DYNAMIC RESPONSE ANALYSIS OF A THREE WHEELER CHASSIS FRAME USING FINITE ELEMENT ANALYSIS

ABSTRACT

A three-wheeler is essentially a motion disturbance vibrating system with the ground providing input. The tyres which are in contact with the ground, convert this input displacement into a forcing function which acts on the unsprung masses, these masses are constrained by linkages so that they follow certain paths. Ride response is dependent on the ground profile, tyre and suspension characteristics, physical dimensions and the inertial properties of the sprung and unsprung masses of the vehicle.

The objective of this thesis is to analyze the dynamic behavior of vehicle using Finite Element modeling. This project also includes the response of the three wheeler chassis frame to road surface inputs and to provide the best vehicle in vibratory motions.

In Finite element modeling, analysis is done to determine the dynamic behavior of the vehicle in Harmonic and Transient excitations. Modal analysis and parametric study has also been carried out. Spectrum analysis is carried out in order to obtain the maximum stresses, as the vehicle running on the road is subjected to the random vibrations.

The results obtained from Finite element modeling in modal analysis were studied and are compared with those of rigid body modeling. In Transient analysis excitation magnitude and

acceleration values at the key nodes are analyzed. From spectrum analysis maximum stress point is noted. Conclusions were derived from the study and suggestions are made to improve the performance of vehicle, thus stability is established.

  Project 24

Tittle: FINITE ELEMENT ANALYSIS OF LPG CYLINDER

ABSTRACT

This project aims at reduction of weight of Liquid petroleum gas (LPG). So, the finite element analysis of Liquefied Petroleum Gas (LPG) cylinders made of Steel and Fiber Reinforced Plastic (FRP) composites has been carried out. Finite element analysis of composite cylinder subjected to internal pressure is performed. Layered shell element of a versatile FE analysis package ANSYS (version 9.0) has been used to model the shell with FRP composites.

A number of cases are considered to study the stresses and deformations due to pressure loading inside the cylinder. First, the results of stresses and deformation for steel cylinders are compared with the analytical solution available in literature in order to validate the model and the software. The weight savings are also presented for steel, Glass Fiber Reinforced Plastic (GFRP) composites and Carbon Fiber Reinforced Plastic (CFRP) composite LPG cylinders. Variations of stresses and deformations throughout the cylinder made of steel, GFRP and CFRP are studied.

A complex orthotropic mechanics of FRP composites has been studied and discussed in brief to have some understanding of behavior of FRP composites. In addition to that an introductory Finite Element Method has also been presented on the basis of which the cylinder has been analyzed.

  Project 25

Tittle: FINITE ELEMENT ANALYSIS AND FATIGUE ANALYSIS OF SPUR GEAR UNDER RANDOM LOADING

ABSTRACT

The gear fitted in the gearbox Armored tracked vehicle is vulnerable to considerable fatigue damage over its life period due to the dynamic excitations caused by the terrain undulations, the rotating wheel and track assemblies. For this purpose, initially static analysis of the model was carried out to validate the model and the boundary conditions correctness. Further Modal analysis is carried out to determine the dynamic characteristics of the gear model. The random load time history is transformed in to frequency domain using Fast Fourier transform to obtain load power spectral density (PSD). Then the stress PSD response is obtained at critical node from the random vibration analysis. Once the spectrum of stress variation is obtained given input to the fatigue analysis and fatigue life is determined by FE package ANSYS 9.0.

  Project 26

Tittle: FINITE ELEMENT ANALYSIS OF A GAS TURBINE ROTOR BLADE

ABSTRACT

In the present work the first stage rotor blade of a two-stage gas turbine has been analyzed for structural, thermal using ANSYS 9.0, which is a powerful Finite Element Software. In the process of getting the thermal stresses, the temperature distribution in the rotor blade has been evaluated using this software.

The design features of the turbine segment of the gas turbine have been taken from the preliminary design of a power turbine for maximization of an existing turbojet engine. It was observed that in the above design, the rotor blades after being designed were analyzed only for the mechanical stresses but no evaluation of thermal stress was carried out. As the temperature has a significant effect on the overall stress on the rotor blades, it has been felt that a detail study can be carried out on the temperature effects to have a clear understanding of the combined mechanical and thermal stresses.

In the present work, the first stage rotor blade of the gas turbine has been analyzed using ANSYS 9.0 for the mechanical and radial elongations resulting from the tangential, axial and centrifugal forces. The gas forces namely tangential, axial were determined by constructing velocity triangles at inlet and exist of rotor blades. The rotor blade was then analyzed using ANSYS 9.0 for the temperature distribution. For obtaining temperature distribution, the convective heat transfer coefficients on the blade surface exposed to the gas have to feed to the software. The convective heat transfer coefficients

were calculated using the heat transfer empirical relations taken from the heat transfer design dada book. After containing the temperature distribution, the rotor blade was then analyzed using ANSYS 9.0 for the combined mechanical and thermal stresses. The radial elongations in the blade were also evaluated.

The material of the blade was specified as N155 but its properties were not given. This material is an iron based super alloy and structural and thermal properties at gas room and room temperatures were taken from the design data books that were available in the library of BHEL(R & D), Hyderabad.

The turbine blade along with the groove is considered for the static, thermal, modal analysis. The blade is modeled with the 3D-Solid Brick element. The geometric model of the blade profile is generated with splines and extruded to get a solid model.

The first stage rotor blade of a two-stage gas turbine has been analyzed for structural, thermal using ANSYS 9.0 Finite Element Analysis software. The thermal boundary conditions such as convection and operating temperatures on the rotor blade are applied on theoretical modeling. Analytical approach is used to estimate the tangential, radial and centrifugal forces

  Project 27 .

Tittle: FINITE ELEMENT MODELING AND STATIC ANALYSIS OF OPEN TOWER

ABSTRACT

Open towers are one among the different types of towers used for the purpose of signal transmission. They are telescopic in nature and are designed in a special manner, which makes the whole structure portable by converting in to a single unit. It consists of main pipe and four supporting members. In order to reduce the weight of the structure it is fabricated with fiber reinforced plastics (FRP). The main pipe is a combination of several sections, which slide into the main member with the help of rollers to form a single unit. The four supporting members can be made integral with the main pipe with the help of a movable flange which slides on the main member.

Finite element modeling of the tower is created in HYPER MESH 07. The analysis is carried out in ANSYS 09. The boundary conditions considered here are wind pressure and top plate weight. The wind pressure is calculated considering velocity of the wind as 90 kmph based on geographical and geothermal factors. This wind pressure is applied as a horizontal force and a moment force at the top of the pipe. The tower analysis is carried out with shell and brick elements. Mesh is created with shell 99 and solid 95. Rod elements are used wherever the direct contact between the surfaces is not there. The maximum displacement occurred at the top and the maximum stress induced in between the layers are

calculated and observed that they are in allowable limits. By this analysis the design of tower is safe based on rigidity criteria and strength criteria.

  Project 28

Tittle: LINEAR AND NON-LINEAR ANALYSIS OF ROTATING GASTURBINE WHEEL CONSIDERING HOTSPINNING

ABSTRACT

A Turbine wheel forms significant part of gas turbine. It forms a connecting media between the

blades and the shaft. The blades due to the exhaust gases from the combustion chamber are set into

rotating motion. The rotor on which the blades are mounted transmitting this motion holds a key point

to better efficiency of gas turbine as a whole unit. Thus more focus should be given to the design of the

turbine rotor.

Hot spinning operation involves mainly the spinning of the turbine wheel at a speed of 1.5 times

the operating speed and at a temperature slightly more than ambient. As a result stresses are produced

which are more than the yield stress which enter into the plastic range, producing a strain outward from

the axis. Now, when the turbine wheel is brought back to zero speed some amount of residual stresses

are stored in the turbine wheel. When the turbine wheel runs under operating conditions the strain

produced should first overcome the residual strain developed towards the center which reduces the

actual stresses.

The stress analysis of the turbine wheel is done by using finite Element Method. This FEM analysis

is done by using ANSYS. Firstly, a linear analysis is done by applying the thermal stresses at operating

conditions. These stresses obtained are without hot spinning. The residual stresses are calculated by

using the nonlinear analysis. Now, these residual stresses are superimposed on the thermal stresses at

operating conditions after hot spinning which are much less than the linear stresses calculated without

hot spinning.

  Project 29

Tittle: SEISMIC AND WIND LOAD ANALYSIS OF SURGE TANK

ABSTRACT

This project is Deals with seismic and wind load analysis of surge tank

The purpose of tank is to limit the number hour’s starts of the pumps placing parts of its stock of water which is maintained under pressure by the air above it at the disposal of the system.

The surge tank can be of the air cushion or diaphragm type. In the air cushion version there is no clear separation between air water since part of the air tends to mix with water it is necessary to restore it by means of air supply units or compressor.

In the diaphragm version neither air supply units nor compressor are needed as contact between air and water prevented by a flexible diaphragm inside the tank.

The following method which is used to determine the volume of surge tank is valid both for horizontal and vertical surge tanks. When calculating the volume of the surge tank it is generally sufficient to consider the first pump only.

In the present work the analysis of surge tank is carried out for:

WIND LOADS

GRAVITY LOADS

SEISMIC LOADS

  Project 30

Tittle: STABILITY ANALYSIS OF STEEL AND COMPOSITE RAILROAD TIES USING FEM

ABSTRACT

A railroad tie, cross tie, or sleeper is a rectangular object used as a base for railroad tracks.

Traditionally, ties have been made of wood, later steel has also been used and concrete is now widely

used along with composite materials. To determine the various stresses in the ties due to static and

dynamic loads, the finite element method is used which is accurate and time saving. The FEM has

developed simultaneously with the increasing use of high speed electronic digital computers and with

the growing emphasis on numerical methods for engineering analysis. The systematic generality of the

finite element procedure makes it a powerful and versatile tool for a wide range of problems. In this

project, the finite element analysis software such as ANSYS R11.0 is used to carry out the stress

analysis.

In this work, 3D analysis is used to carry out a railroad tie made of steel and composite

materials under static and dynamic loads. A detailed model of the tie is created using ANSYS geometric

modeling options. Due to static loading the stress distributions and deflections are investigated. The

plots of distribution of stress is depicted with the results and their influence on the tie is discussed.

Further modal, harmonic and transient analysis is performed to obtain dynamic stability.The analysis

suggests that composite ties can be used instead of steel ties and stress in the ties can further be

reduced by increasing the thickness of composite ties and can have greater life. But the major problem

with composites is higher initial cost.

  Project 30

Tittle: THERMAL ANALYSIS OF CLAMSHELL HEAT EXCHANGER

ABSTRACT

Clamshell Heat exchangers are used in the residential furnaces, for room heating purposes. The clamshell heat exchanger is subjected to heating and cooling cycles alternatively. The hot gases after combustion in the burner flows through the heat exchanger for 150 seconds heating the clamshell heat exchanger. This constitutes the heating cycle. The flow of hot gases from the burner is stopped after the completion of heating cycle. Now the cold air from the atmosphere is blown over the hot clamshell heat exchanger for next 150seconds. Thereby heating the air and cooling the clamshell heat exchanger. This constitutes the cooling cycle .In this process of heating and cooling in small time span of 150seconds, the clamshell is subjected to large thermal stress variations. These stress variations induce the thermal fatigue in the material and lead to formation of cracks in the clamshell heat exchanger.

The heating and cooling cycles are simulated using the principles of Finite element methods and the analysis software ANSYS 7.1. Firstly, the transient fluid flow analysis of gas flow region is performed to plot the velocity, pressure and temperature distributions in it. After the combustion in the burner, the gases attain a temperature of 1020F. These gases are blown into the heat exchanger with the help of an indoor blower for 150 seconds. The pressure gradient induced by the blower (p = 0.0093128 lb/in2) and temperature of the gases from the burner (1020 F) are applied as boundary conditions for the fluid flow analysis of gas flow region. With the obtained temperature distribution in the gas flow region as input, the thermal analysis of clamshell heat exchanger is performed to plot the temperature distribution in it. With the obtained temperature distribution in the clamshell heat exchanger as input, the structural analysis of clamshell heat exchanger is performed to plot the thermal stress distribution in it.

In the cooling cycle, the air is blown over the hot clamshell heat exchanger with the help of the blower for next 150 seconds. For this purpose a two-inch airflow region is modeled over the clamshell heat exchanger. The temperature distribution in the clamshell heat exchanger after heating cycle is given as initial condition i.e., at t=0. The pressure gradient induced by the blower (p = 0.127781e-3 lb/in2) is applied as boundary condition. With the above initial and boundary conditions the fluid flow analysis of airflow region over the clamshell heat exchanger is performed to plot the velocity, pressure and temperature distributions in it. With the obtained temperature distribution in the airflow region as input, the thermal analysis of clamshell heat exchanger is performed to plot the temperature distribution in it. With the obtained temperature distribution in the clamshell heat exchanger as input, the structural analysis of clamshell heat exchanger is performed to plot the thermal stress distribution in it. Using these stress distributions the thermal fatigue life is calculated with the help of the Modified Goodman Diagram.

The clamshell heat exchanger is found to be failing after 9399.37 cycles due to thermal fatigue near the first bend region. The large thermal gradient existing in the region near the first bend is observed to be the critical parameter for the failure of the clamshell heat exchanger

Title:Design and development of mounting bracket of Honda city car using CAE techniques .

Imagine replacing metal with a strong durable thermoplastic compound. One that consolidates

parts to reduce expensive assembly and fabricating costs.

When we go for replacing metal parts with plastics, then so many things come to our

mind. Starting from material selection, we proceed with the required design for the proposed

plastic part to withstand the requirements then the processing of the proposed part taken

place.

Hence, part design plays a vital role because; in the case of plastics the design of the

part is done with a lot of care. Plastic part design is not as simple as the metal part design. as

The design of the plastic part is done by taking a lot of things into consideration. Things like

material selection and processing of the designed part with the material directly depend on the

design of the part. A little mistake in design can lead to total part failure. So, especially when we

switchover to plastics from the metal side, we got to take care of all the correct design factors

as the strength of the plastic part will be supposed to equal an exceed the strength of the metal

part.

STRUCTURAL ANALYSIS OF AN L - SHAPED ALUMINUM BEAM

SOFTWARE USED

ANSYS 8.0

TYPE OF ANALYSIS STEADY STATE STRUCTURAL ANALYSIS

OBJECTIVE OF THE PROJECT

To find the stresses and deflections of a simple 'L'-shaped aluminum beam with one end cantilevered and a point load at the other end

ABSTRACT

An L-shaped aluminum beam cantilevered at one end and subject to a concentrated load at the free end is used to study stress and strain transformations along with principal stress and strain calculations. Equations of solid mechanics can be used to calculate the state of stress at a point close to the cantilevered edge and on the longitudinal axis of the beam. Stress transformation equations are then used to evaluate principal and Von-Mises stresses. Then, ansys finite element package is used to evaluate Von-Mises stress for the L-shaped beam at the same point where the states of stress and strain were defined.

"L"-shaped aluminum beam with one end cantilevered and a point load at the other end is created using Ansys 8.0 software which works on finite element method. The model is being created using Direct Generation Method (creating nodes and elements). To find the stresses, deflections and bending moment when point load is applied on other end.

FINITE ELEMENT ANALYSIS OF TUNING FORK

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SOFTWARE USED

ANSYS 8.0

ANALYSIS TYPE

MODAL ANALYSIS

OBJECTIVE OF THE PROJECT

To determine the vibration characteristics (natural frequencies and mode shapes) of a Tuning fork.

ABSTRACT

Every component is subjected to vibrations due to natural frequencies and at resonating frequencies we get different mode shapes. While developing prototype of a component, it is required to find out all the natural frequencies the corresponding mode shapes. Frequencies beyond a certain values badly effects the functionalities of the component and after the Modal Analysis, if we find that the values are beyond the desirable range, than we will have to either change the design or material. The vibration characteristics (natural frequencies and mode shapes) of a structure or a machine component can also be the starting point for another, more detailed, dynamic analysis, such as a transient dynamic analysis, a harmonic response analysis, or a spectrum analysis. The natural frequencies and mode shapes are important parameters in the design of a structure for dynamic loading conditions.

Thermal Analysis of Railway Wagon Brake Shoe

Analysis and Design of Underground Storage Tanks of Polyethylene and Polymers.

Analysis of Ship Structures

Integrated approach through CAE for Design & Devlopment of a Cooling Fan used in a Hand-Grinding Machine.

Design development of air intake manifold for four wheeler engine.

Design and exploration of bumper systems using advanced cae techniquces.

Design & Structural analysis through cae of gear control box housing used for manual transmission in four wheeler.