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Presented By, Design and of Gear Control Box Base Plate Made of Polymer Analysis Composite Material through CAE 1.Kiran Thore 2. Vikas Patil 3.Vivek Kadu

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Outlines: Outlines: Introduction. Part Design. FEA Modeling. Quality Checks. Linear Analysis. Thermal Analysis. Results & Discussion. Conclusion.References.

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Introduction: Composite Material: “material consisting of more than one macroscopic phase” “material consisting of more than one macroscopic phase” matrix, disperse phase, interface

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Categories: Subdivision by Matrix material: Polymer matrix composite : PMC Metal matrix composite : MMC Ceramic matrix composite : CMC Disperse phase: particles,whiskers,short fibers, Continuous fibers, sheet laminates random/ preferred orientation Isotropic/anisotropic

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Why Composites for Cars? Glass Fiber Composites can reduce weight by % Data Base Design Methodologies Processing Technologies Material Crash Models Rapid Cure Technologies Joining Methods NDT Recycling Carbon Fiber Composites can reduce weight by 40-60% Weight Reduction = Fuel Economy & Emission Reductions

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Largest Focus Areas - Polymeric-matrix composites processing - Aluminum sheet formation and fabrication - Aluminum and magnesium casting Missions: - Support development of cost-effective materials and materials manufacturing processes required to achieve successful commercial introduction of fuel- efficient, low-emission, terrestrial transportation vehicles. Automotive Light weighting Material:

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Lightweight MaterialMaterial Replaced Mass Reduction (%) High Strength SteelMild Steel10 Aluminum (AI)Steel, Cast Iron MagnesiumSteel or Cast Iron MagnesiumAluminum Glass FRP CompositesSteel Graphite FRP CompositesSteel Al matrix CompositesSteel or Cast Iron TitaniumAlloy Steel Stainless SteelCarbon Steel Weight Savings and Costs for Automotive Light weighting Materials

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Base Plate Project Component:

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Part Design: 1.Original Design. 2.Modified design (features modified in the component) 3.Thickness control.

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Original Design: 1. Solid Model is Generated using CATIA V5 R16.

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Modified Component: 1.Wall Thickness is increased & taken 7mm. 2.Rib is generated in front wall. 3.Side Wall height is increased.

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Drafting of Modified Component: Top ViewFront View Side View

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Comparison between original & modified model: Rib is Inserted Side wall Height is increased Wall thickness is increased Original Model Modified model

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Material Detail: Required material Properties High impact resistance High temperature Dimensional stability Chemical resistance Stiffness Wear resistance Part weight

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Structural grade Epoxy – 50% Glass Fiber Reinforced material. Commercial name: Vyncolit EM 7302 Hardware Grade Epoxy. Manufacturer: sumitomo Bakelite Phenolics (USA). Mechanical PropertiesMetric Hardness, Rockwell M105 Tensile strength at Break138 Mpa Flexural Modulus24.0 Gpa Flexural Strength345 Mpa Compressive Strength255 Mpa Izod Impact, Notched16.0 j/cm

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Electrical PropertiesMetric Dielectric Constant5.80 Dielectric Strength12.8 kV/mm Dissipation Factor Arc Resistance120 Sec. Thermal PropertiesMetric CTE, Linear 20ºC120 µm/m-ºC Thermal conductivity0.420W/m-K Deflection Temperature At 1.8Mpa >=250 ºC

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Physical PropertiesMetric Density1.85 g/cc Linear Mold shrinkage cm/cm Descriptive PropertiesMetric ColorBlack Natural Main FillerGlass Fiber Molding MethodCompression, Transfer

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Methodology & Strategy of Analysis: Solid Modeling FEA Modeling + Quality Checks Applying Material Properties, Boundary Conditions & Analysis

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FEA Modeling: Mesh details: 1.Hypermesh 8.0 platform is used for meshing. 2.FE model generated on mid surface of component. 3.Mixed elements (Quad & Tria) are used for meshing. 4.2D Shell elements are used (2D shells can be drawn as a line, 3D as an area.) 5.Average 4.0 mm & min 2.0 mm element size is considered. 6.Washer is created near holes. 7.Dense meshing near hole areas.

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Quality Checks: Quality is checked on different parameters : warpage, aspect ratio, length; jacobian

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1 < Aspect Ratio This is the ratio of max element edge length to minimum edge length. Ideal value = 1 (Acceptable is less than 5) Jacobean Check > Ideal Value = 1.0 (Acceptable more then 0.6) Jacobian is a scale factor arising because of transformation of co-ordinate system.

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1 warpage Check Warp angle is out of plane angle. Ideal value = 0 0 (Acceptable is less than 10 0 ) Element length Average = 4.0mm Maximum= 6.00 mm Minimum = 2.00 mm

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FREE EDGES CHECKING Any quad element having 4 free edges

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Boundary Condition Details: Essential and Natural B.C. Boundary conditions (BCs) come in two basic flavors: essential and natural. Essential BCs directly affect DOFs. Natural BCs do not directly affect. 1. If a boundary condition involves one or more degrees of freedom in a direct way, it is essential. An example is a prescribed node displacement. 2.Otherwise it is natural.

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Boundary Conditions in Structural Problems: Essential boundary conditions in mechanical problems involve displacements (but not strain-type displacement derivatives). Support Conditions Supports are used to restrain structures against relative rigid body motions. The resulting boundary conditions are often called motion constraints.

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Essential B.C. Natural B.C.

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Linear Analysis: 1.Analysis is performed in optistruct 8.0, package of hyper-works. 2.Analysis has been carried out for different amount of loads such as 1 N, 2 N, 3 N, 4 N, 5 N & 10 N 3.Displacement of the component and von-mises stress is found out for different amount of loads

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1 1 N of Load: Displacement Von Misces stress

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2N of Load Displacement Von Misces stress

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3 N of Load: Displacement Von Misces stress

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4 N of load: Displacement Von Misces stress

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5 N of Load: Displacement Von Misces stress

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10 N of Load: Displacement Von Misces stress

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1 Thermal Analysis: 1.Thermal analysis is performed in optistruct Stability of the component for different amount of temperature is found out. Temperature Loading

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100 ºC Temperature: Displacement Von Misces stress

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125 ºC Temperature: Displacement Von Misces stress

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135 ºC Temperature: Displacement Von Misces stress

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150 ºC Temperature: Displacement Von Misces stress

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175 ºC Temperature: Displacement Von Misces stress

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Result & Discussion: Linear Static Analysis: 1.Up to 3n-4Nn of load Component is showing Stresses below than than the tensile strength at break of the used material. Thermal Analysis: 1.Used Material is having good thermal stability which it shows up to the 150 ºC Temperature 2.Displacement is Acceptable up to the range of 3-4mm. 3. Above the temperature of 150 ºC, Displacement is also increasing. Which is above the target displacement.

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Conclusion Composite Materials are the highly preferred material now a days. Approach for weight reduction & High strength to weight ratio of material is considered. If referred steps can be molded with no fault then desire goal can be achieve. Further different more analysis like non-linear, impact can be performed for more accurate results.

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References:- Modern plastics encyclopedia handbook, New York, McGraw-hill. Plastics processing handbook, Berins, Hanser Pub.. Processing of composite material, B.T. Astrom Handbook of Enineering material, Vol.-2 (composite), American society for materials.

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Thank You…

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