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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 20 -30% 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 Iron40 - 60 MagnesiumSteel or Cast Iron60 - 75 MagnesiumAluminum25 - 35 Glass FRP CompositesSteel25 - 35 Graphite FRP CompositesSteel50 - 60 Al matrix CompositesSteel or Cast Iron50 - 65 TitaniumAlloy Steel40 - 55 Stainless SteelCarbon Steel20 - 45 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 Factor0.0170 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 shrinkage0.00100 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 8.0. 2.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. www.finitetoinfinite.com www.rogancorp.com www.moldmaster.comwww.moldmaster.com. www.ides.com

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Thank You…

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