FINITE ELEMENT ANALYSIS of FARM TRACTOR'S

FRONT AXLE USING CAE TOOLS

A DISSERTATION SUBMITTED
IN THE PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR THE A WARD OF THE DEGREE OF

MASTER OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
(MACHINE DESIGN^
BY
VnCAS KUMAR
209435
(Session 2009-2011)

UNDER THE GUIDANCE OF

DRSURJITANGRA

DR. VINOD KUMAR MITTAL

^mT^TOli^^?!

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
(Institution of National Importance)
KURUKSHETRA -136119, HARYANA
I
 CERTIFICATE

This is to certify that Mr. Vikas Kumar, Roll no. 209435 has successfiiUy completed his

dissertation entitled "FINITE ELEMENT ANALYSIS OF FARM TRACTOR'S FRONT

AXLE USING CAE TOOLS" being submitted in the partial fulfillment of the requirements

of the award of the degree of master of Technology in Mechanical Engineering (Machine

Design) at National Institute of Technology, Kurukshetra, is an authentic record of original

work carried out by him under our guidance and supervision.

The work embodied in this dissertation is his bonafide research work, and has not been

submitted elsewhere for the award of any other degree or diploma.

(Dr . Surjit Angra) (Dr. Vinbd Kumar Mittal)

Professor Associate Professor

Mechanical Engineering Department Mechanical Engineering Department

National Institute of Technology National Institute of Technology

Kurukshetra-136119 Kurukshetra- 136119

India India

II
 ACKNOWLEDGEMENT
At the very outset, I would like to record my heartfelt gratitude to my respected teachers and

thesis supervisors Dr. Surjit Angra and Dr. Vinod Kxmiar Mittal for their invaluable guidance,

cordial advice and constant encouragement throughout this research. I feel very fortunate to have

this opportunity to work with them and I shall always remain obliged to their greatness in

devoting a large share of their valuable time and knowledge to this work.

I wish to express my sincere gratitude Dr. S. S. Rattan, Professor & Head, Mechanical

Engineering Department, NIT Kurukshetra for all his possible support during the execution and

completion of this thesis.

I would like to dedicate this project work to my parents and my

Mends who are great source of support & encouragement, especially in all of our academic

endeavors. I shall be failing in my duty if I do not express thanks to my friends especially Om

prakash and Gopal Krishan for their ungrudging help and suggestions.

I find myself spellbound to acknowledge thanks to my wife Kavita for her silent support,

patience, encouragement and affection without which this work would never have been possible.

4^
(VDCAS KUMAR)

III
 ABSTRACT

Farm tractor is a vehicle which is used as a portable machine to do various usefiil works such as

farming, haulage, transportation, heavy earthmoving etc. Tractor is considered as off-road

vehicle to do work in the field. Tractor consists offi-ontaxle which is a dead axle and supports

the whole body on the front. It is one of the safety components. As Front axle is subjected to

stresses caused by

• Load due to thefi-ontpart of tractor (Vertical force)

• Inertia force while applying the brake (braking force)

• Uneven reaction from the road or field's pits

• Sudden load due to the lift of the front part of tractor during pulling the loaded trolley.

which leads to stresses and deformation in front axle so a structural analysis of

front axle has been carried out. Axle bending was attributed due to some form of resistance to the

frontal movement of tractor during motion and the trolley payload is acting against this frontal

resistance. The main objective fimction of this work is to perform the finite element analysis of

front axle and minimize the deflection in front axle by changing the external parameter (size &

shape) of the front axle. The behavior of front axle is simulated in ANSYS-V12. Based on the

analysis, load was derived to obtain the same deflection magnitude as observed in the field

(experimentally Load was calculated by the engineers of Mahindra & Mahindra Ltd.). The

company engineers have modified thefr front axle and done the analysis. Results of their analysis

are used for fiuther analysis. Further modifications are done on the FE model of front axle in

ANSYS-V12 and the modified model is subjected to same loading and boundary conditions.

IV
The results are compared and verified with available experimental and standard results.

Compared results give a fair correlation between the FE analysis through ANSYS-V12 and the

available experimental results. Thus Modified design of the front axle can be considered for the

implementation. The modified design also achieves the reduction in weight of front axle thus

reducing the material cost and time which is beneficial for mass production.

V
 CONTENTS
Page No.

Certificate II

Acknowledgement III

Abstract IV

Contents VI

List of Figures IX

List of Tables X

1. INTRODUCTION 01-04

2. LITERATURE REVIEW 05-08

3 INTRODUCTION TO CAE TOOLSAND CAE SOFTWARE'S 09-18

3.1 INTRODUCTION 09

3.2 APPLICATION AREA 10

3.3 CAE AND PROCESS MANAGEMENT 11

3.4 COMPUTER AIDED ANALYSIS 13

3.5 LIST OF AVAILABLE CAE SOFTWARE 13

3.6ANSYS-11 15

4. COMPUTER AIDED DESIGN AND METHODOLOGY 19-26

4.1 COMPUTER AIDED DESIGN 19

4.1.1 BASICS OF CAD SYSTEMS 20

4.1.2 SOFTWARE TECHNOLOGIES 21

VI
 4.1.3 HISTORY 21

4.1.4 FUTURE DIRECTION FOR CAD 22

4.1.5 CAPABILITIES 23

4.1.6 USES 24

4.1.7 APPLICATION AREA 25

5. FINITE ELEMENT ANALYSIS (FEA/FEM) 27-42

5.1 INTRODUCTION 27

5.2 BRIEF HISTORY 28

5.3 FINITE ELEMENT METHOD (FEM) 29

5.4 FINITE DIFFERENCE METHOD (FDM) 31

5.5 COMPARISON OF FEM AND FDM 31

5.6 PROCEDURE OF FEM 32

5.7 PRACTICAL FEM THROUGH FEASOFTWARES/FEA TOOLS 33

5.8 KEY ASSUMPTIONS IN FEA 34

5.9 SOURCES OF ERRORS IN FEA 36

5.10 ADVANTAGES AND DISADVANTAGES OF FEA 36

5.11 APPLICATIONS OF FEA 37

6. FE MODELING METHODOLOGY AND ANALYSIS 43-49

6.1 ANSYS 43

6.1.1 INTRODUCTION 43

6.2 STATIC ANALYSIS 43

6.2.1 OVERVIEW TO THE PROBLEM 44

VII
 6.2.2 MATERIAL PROPERTIES 45

6.2.3 MESH GENERATION 45

6.2.5 APPLIED CONDITIONS AND LOADING . 46

6.2.6 MODEL DISPLAY 48

6.2.7 SOLUTION 48

6.2.8 POST- PROCESSOR 49

7 RESULTS AND DISCUSSION 50-53

7.1 STATIC STRUCTURAL ANALYSIS RESULTS OF FONT AXLE

OF FARM TRACTOR 50

7.2 COMPARISON OF FEA RESULTS OF PRESENT MODEL 52

8 CONCLUSIONS 54

8.1 CONCLUSION & DISCUSSION 54

8.2 SCOPE FOR FUTURE WORK 54

REFERENCES 55-56

VIII
 LIST OF FIGURES
Figure Title Page
No.
Fig. 1.1 Front Axle of a Fann Tractor 3

Fig. 3.1 Various Computer Aided Technologies 12

Fig. 5.1 Procedure of FEM 32

Fig. 5.2 Linear Analysis 38

Fig. 5.4 Material Non-Linearity 39

Fig.5.5 Types of Dynamic Analysis 40

Fig 5.6 Modes of heat transfer analysis 41

Fig. 5.7 Stress and Number of cycle Cvuve for fatigue analysis 42

Fig. 6.1 Fig. 6.1 Geometric model of front axle 44

Fig. 6.2 3-D Mesh Model 46

Fig. 6.3 Static Load 47

Fig. 6.4 AppUed constraints on the front axle 48

Fig. 7.1 Equivalent (Von-Mises) Stress for each element in the front axle. 50

Fig.7.2 Equivalent (Von-Mises) Stress for each element in the front axle. 51

Fig.7.3 Total Deformation for each element in the front axle 51

Fig. 7.3 Total Deformation for each element in the front axle. 52

IX
 LIST OF TABLES

Table Title Page No.

Table 3.1 Software and their provider companies 14

Table 6.1 Parameters of St 37-2 Front Axle 45

Table 7.1 Result Comparisons 52

X
 CHAPTER 1
INTRODUCTION

1.1 INTRODUCTION
As this work is based on Finite Element Analysis, it is required that a component on which

analysis is to be done should have practical application and result of experimental analysis could

be compared with FE analysis results for validation. The component chosen for this purpose is a

Farm Tractor's front axle which finds widespread applications in all four wheeler vehicles. The

CAD model of front axle has been generated in workbench of ANSYS-V12 and itself imported

in model analysis part of ANSYS-V12.

1.2 AXLE

An axle is a central beam for a rotating wheel or gear. On wheeled vehicles, the axle may be

fixed to the wheels, rotating with them, or fixed to its surroundings, with the wheels rotating

aroimd the axle. In the former case, bearings or bushings are provided at the mounting points

where the axle is supported. In the latter case, a bearing or bushing sits inside the hole in the

wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the

latter type is referred to as a spindle.

On cars and trucks, several senses of the word "axle" co-

occur in casual usage, referring to the shaft itself, it's housing, or simply any transverse pair of

wheels. The shaft itself rotates with the wheel, being either bolted or splined in fixed relation to

it, and is called an "axle" or "axle shaft". However, it is equally true that the housing around it

(typically a casting) is also called an "axle" (or "axle housing"). An even broader (somewhat

figurative) sense of the word refers to every transverse pair of wheels, whether they are
1
connected to each other or not. Thus even transverse pairs of wheels in an independent

suspension are usually called "an axle". There are two type of axle:

1. Rear Axle (Live Axle)

2. Front Axle (Dead Axle)

A live axle is so-called because it contains a gearing unit that translates the

engine power delivery from longitudinal (bumper-to-bumper orientation) to lateral (side-to-side

orientation) so that the tires can utilize the power. These are the axles that drive the wheels. The

rear axles on a rear-wheel drive and the front-axles on a front wheel drive are live axles.

Dead axles are used on the non-driven wheels. Eg. Front axles in a tractor, truck, other

automobile. A dead axle does nothing more than link the left and right wheels, and contains no

power-delivery imit. Axles can be subdivided into either straight, drop, raised and independent

categories.

The Front axle (fig. 1.1) of a farm tractor is acts like a simply supported beam

member with the partial tractor weight acting in the centre and ends of front Axle being

subjected to groimd reactions through the front wheels. In a rear drive vehicle, front wheel are

free to move at any speed according to the speed of the vehicle. The mechanism of the front axle

in tractor is a simple one. The front axle in rear drive farm tractor act like a simple beam. The

work described here forms part of a designing project carry out the design optimization of front

axle using the ANSYS software. Due to market competitiveness it is important for clients to

be able to produce an optimized design (with minimum weight).

 Fig. 1.1 Front Axle of a Farm Tractor

Typical design variables forfrontaxle are the width and depth, as the length of the axle has to be

same to maintain the distance between two front wheels. While carying the load, in case of

beams, the transverse section of the beam plays very important role to bear the load. The lengA

of the axle we are not changing the other dimensions will affect the stresses and deformation in

the front axle. The objectivefrmctionwas to minimize the deflection in front axle by changing

the external parameter (Size & Shape) of thefrontaxle. A number of random designs

would be generated by varying the values of the design variables within the specified

limits before the optimizer homed in to the best design.

As Front axle is subjected to various forces which leads to stresses and deformation infrontaxle

so a structural analysis offrontaxle has been carried out? The main objective of this dissertation

work is to perform the Finite Element Analysis of Farm Tractorfrontaxle using CAE Tools, so

as to determine the total deformation and stress distribution in the front axle. The deformation

and stress contours have been plotted and patterns are studied. The results are compared and

verified with available experimental and standard results. The optimization of front axle also
achieve the reduction in weight of the axle, thus reducing inertia load, reducing tractor weight,

improving the engine performance and fuel efficiency and reducing the overall cost.
 CHAPTER 2

LITERATURE REVIEW

There is a vast amount of literature related to Finite Element Analysis. Many research

publications, journals, reference manuals, newspaper articles, handbooks; books are available of

national and international editions dealing with basic concepts of FEA. Many other publications

indicate the success story of implementation of FEA on various components. The literature

review presented here considers the major implementation of FEA in developing the axle design

for different vehicles.

Ali Jafari et al [1] have done Stress Analysis and optimization of Front Axle of JD 955 Combine

Harvester under Static Loading. JD 955 combines manufactured by Iran Combine Manufacturing

Company was modified. Resulting fi-om the applied modifications, total weight and the loads

applied onfi-ontaxle of modified combine were increased. Stress analysis offi-ontaxle of JD 955

combine vmder static loading conditions resultedfi-omthe applied modifications was performed

by using finite element method.

Dilip K Mahanty et al [2] have performed the analysis and weight reduction of a tractor's front

axle. Engineering components with optimum use of material and easy manufacturability is a

direction where prior simulation through finite element method is found to be very usefiil. The

objective was to analyze the new design of the fi-ont axle of tractor for different Test load

conditions. The existing design has no field failure reports; so the results of the existing design

were taken as basis for comparison with results of the proposed models. Based on the finite

element analysis results, redesign was carried out for the front axle for weight optimization and

easy manufacturability. The proposed designs were evaluated for selected worst load cases of the
existing design. The finite element analysis of new models yielded displacements and stresses

close to the existing design. The increase in stresses was close to 15 % for all five models. The

increase in displacement was not significant but all the new designs conceived had met the

structural requirement. It was also observed that for the proposed designs there was a significant

reduction in weight (approximately 40 %) and the proposed models did not involve a lot of

welding, thereby significant savings of manufacturing was observed. This analysis work

showcases the use of finite element analysis as a method for reduction of cost in terms of

materials and manufacturing.

Dr. Sajan Pawar et al [3] performed the Non Linear Analysis of Farm Tractor Front axle using

ABAQUS CAE. The Non Linear behavior of axle was simulated in ABAQUS CAE. Non

Linearity was simulated by putting the material non linearity data in the material stress strain

curve. Based on the analysis load was derived to obtain the same deflection magnitude as

observed in thefield.To confirm this load a physical test was done in Test Lab on physical axle.

Modifications are done on the FE model in Abaqus CAE and the modified model is subjected to

same loading and boundary conditions. The output graph of load verses deflection of both failed

and modified axle is compared against the Lab Test results. Compared results gave a fair

correlation between the FE analysis through ABAQUS and the Physical Test. Thus giving

confidence in implementing the Modified design.

N. Le6n et al [4] have reduced the Weight of a Frontal Truck Axle Beam Using Experimental

Test Procedures to Fine Tune FEA. The use of finite element methods to improve its product

quality while reducing development time. The objective of reducing material and manufacturing

costs was followed while maintaining the stress levels under the values previously obtained with

earlier products that had worked reliable during several years. For the finite element analysis,
MSC.Patran/MSC.Nastran V. 8.0 was used. The FEA results obtained were experimentally

validated through DIRONA standard experimental test procedures.

Abhijit P. Bimale et al [5] has optimized the shape of front axle beam of truck. Optimization of

front axle beam is necessary to improve strength to weight ratio for a given factor of safety

without altering any assembly parameters. This is achieved by using high-end optimization tool

HyperWorks OptiStrct. Shape optimization tool in HyperWorks OptiStrct is used for analysis.

Having mass production, reducing 5% mass per FAB gives large material saving. Saves time as

well as cost not only of manufacturing different prototypes & testing them but also of creating

different 3D models. All the defined shapes can be given for optimization simultaneously or with

different combinations, with number of load cases; this gives a lot of flexibility and leads to

faster design cycles.

Leon et al. [6] used experimental and numerical methods, for the stress analysis of a frontal truck

axle beam. The results obtained by finite element method were verified experimentally using

photo stress.

Mahanty et al. [7] performed an experimental and numerical analysis of a tractor's front axle.

Based on finite element analj^is results redesign was carried out for the front axle for weight

optimization and easy manufacturability. Five different models were proposed based on ease of

manufacture and weight reduction. The results obtained by finite element method were analyzed

by thirteen different certification test load conditions.

Maly et al [8] used experimental and numerical methods, for design change from casting to

welding for an axle casing.

M.M. Topa9 et al [9] has predicted fatigue failure of a rear axle housing prototype by using finite

element analysis. A premature failure that occurs prior to the expected load cycles during the
vertical fatigue tests of a rear axle housing prototype is studied. Design enhancement solutions

were proposed to increase the fatigue life of the housing. FE analyses showed that the regions,

where fatigue failure was initiated diiring vertical fatigue tests, are subjected to stress

concentration, which can cause a premature failure before the predicted 5 xlO'^S minimum cycles

limit. The results are in agreement with the results of vertical fatigue tests. Premature fatigue

failure of a truck rear axle housing prototype was investigated by using finite element analysis.

As the various scientist and engineers have performed different analysis offi"ontaxles and try to

optimize the design according to the requirement of customer. An attempt to redesign the front

axle of farm tractor have been done in this work, and tried to minimize the deflection and weight

of the front axle so that better performance of the tractor has been achieved.
 CHAPTER 3

INTRODUCTION TO CAE TOOLS AND CAE SOFTWARE'S

3.1 INTRODUCTION

Computer-aided technologies are a broad term describing the use of computer to aid in

the design, analysis, and manufacture of products.

Computer Aided Engineering is a technology for supporting engineers in tasks such as analysis,

simulation, design, manufacture, planning, diagnosis and repair. Software tools that have been

developed for providing support to these activities are considered CAE tools. CAE tools are

being used, for example, to analyze the robustness and performance of components and

assembUes. It encompasses simulation, validation and optimization of products and

manufacturing tools. In the fiiture, CAE system will be major providers of information to help

support design teams in decision making.

CAE embrace the application of computers from preliminary design (CAD) through production

(CAM). Computer Aided Design, which is usually associated with computerized drafting

applications, also includes such diverse application programs such as those for calculating the

dimensional stack-ups due to tolerances, ergonomic studies with virtual design optimization.

Computer Aided Analysis includes finite element and finite difference method for solving the

partial differential equations governing solid mechanics, fluid mechanics and heat transfer, but it

also includes diverse program for specialized analyses such as rigid body dynamics and control

system modeling.
Computer aided manufacturing (CAM) includes programs for generating the instructions for

computer numerically controlled (CNC) machining to production and process scheduling and

inventory control. Recently, manufactures have been asked to design their products for eventual

recycling, and this aspect of engineering will undoubtedly fall imder the umbrella of CAE, but as

of yet it doesn't have its own acronym. Studies say that any design engineer can save approx.

30% of time and cost by CAE tools.

Areas covered by CAE tools:

• Stress analyses on components and assemblies using FEA (Finite Element Analyses)

• Thermal and fluid flow analyses by Computational fluid dynamics (CFD)

• Kinematics

• Mechanical Event Simulation (MES)

• Analyses tools for process simulation for operations such as casting , molding, and die

press forming

• Optimization of the product or process

hi general, there are three phases in any Computer Aided Engineering task:

• Pre-processing - defining the model and environmental factors to be applied to it.

• Analyses solver

• Post-processing of results

3.2 APPLICATION AREA

• Aerospace

• Automobiles

• Metal Forming

10
 Sheet Metal Forming

Drop testing

Can and shipping container design

Electronic component design

Glass fonning

Plastic, mould and blow fonning

Biomedical

Metal cutting

Earthquake engineering

Failure analyses

Sports equipments

Civil engineering

3.3 CAE AND PROCESS MANAGEMENT

The various activities that make up Computer Aided Engineering are an essential part of the

product design cycle to speed up the design cycle, to ensure that the products designed are of

higher quality, and to reduce cost of the final product. Broadly, the tasks the designer has to carry

out, exists in two categories the first is model creation, while the second covers reporting and

interpretation of results.

Regardless of the category, many of the tasks are tedious; requiring a considerable attention to

detail one way to improve a model is to use a checklist: element quality checks are an excellent

example of checklists. But suppose as a result of oversight or of ignorance, the checklist has not

been applied? Even worse, suppose the designer has neglected to report any assumptions in the

11
model and suppose the violation of tfiese assumptions can lead to disaster: Clearly, the potential

impact of CAE errors can be very high.

Otiier Computer Aided Technologies are:-

The term CAD/CAM (computer-aided design and computer-aided manufacturing) is also often

used in the context of a software tool covering a number of engineering fimctions.

• Computer-aided architectural design (CAAD)

• Computer-aided design and drafting (C ADD)

• Computer-aided drafting (CAD)

• Computer-aided electrical and electronic design (ECAD)

• Computer-aided industrial design (CAID)

• Computer aided engineering (CAE)

Fig. 3.1 Various Computer Aided Technologies

12
 Knowledge-Based Engineering (KBE)

Manufacturing Process Management (MPM)

Manufacturing process planning (MPP)

Manufacturing resource planning (MRP)

Product data management (PDM)

Product lifecycle management (PLM)

Reverse engineering (RE)

3.4. COMPUTER AIDED ANALYSIS (CAA)

Computer Aided Analysis (CAA) is a technique by which approximate solution of a numerical

problem can carry out. Computer Aided Analysis includes finite element analysis for solving the

partial differential equations governing solid mechanics, fluid mechanics, and heat transfer, but it

also includes diverse programs for specialized analysis such as rigid body dynamics and control

system modeling. The two most widely used methods in computer aided analysis are Finite

Element methods and Finite Difference method. The later are used mainly for problems in

Computational Fluid Dynamics (CFD), while the former is used in a wide range of applications

3.5 LIST OF AVAILABLE CAE SOFTWARE

For the purpose of CAD model generation and Finite Element Analysis there are many software

packages available in the market. List of such software and name of company providing the

software is given in Table- 3.1

13
S.NO. Software Company

1. Abaqus Dassault System

2. Abaqus Explicit Dassault System

3. Adams MSC software Corporation

4. Ansys AnsySjIns

5. CASTFLOW Walkingtone Engg, Inc

6. CATIA Dassault System

7. CFX AnsySjIns

8. FE-safe Safe Technology Ltd

9. Fluent Ansys.Ins

10. Hyperview Player Altair Engg. Inc.

11. HyperMesh Altair Engg. Inc.

12. Ls-dyna Liver more softwareTech. Group

13. MATLAB The Mathworks

14. Motion-solve Altair Engg. Inc.

15. MSC Fatigue MSC software Corporation

16. MSCNastran MSC software Corporation

17. NX-Ideas UGC Plam software

18. NX-Nastran UGC Plam software

19. Optistruct Altair Engg. Inc.

20. Pam crash ESE Group

21. Radioss Altair Engg. Inc.

22. Solid WORKS 3D Vision Technologies

14
 23. Star-CD CD-adapco

24. Unigraphics UGC Plam software

Table- 3.1 Software and their provider companies

From all of the above software's we have used:

ANSYS-12

3.6 ANSYS-12
ANSYS, developed by ANSYS, Inc., USA, is a dedicated Computer Aided Finite Element

Modelling and Finite Element Analysis tool. ANSYS is known as the standard in the field of

Computer Aided Engineering. The Graphical User Interface (GUI) of ANSYS enables the user to

work with 3-dimensional (3D) models and also generate results from them. You can perform a

variety of tasks ranging from Finite Element Analysis to complete Product Optimization

Analysis using ANSYS.

System Requirements:

The following are the system requirements to ensure the smooth running of ANSYS on your

system:

• System unit: An Intel Pentium 4 or AMD 64, running Microsoft 2000 Professional Edition,

Windows XP 32-bit, or Windows XP x64 on it.

• Memory: 512 MB of RAM is the minimum requirement for all applications. However, for 64-

bit systems, 1 GB of RAM is the minimum requirement.

• Disk drive: 2.2 GB Disk Drive space (Minimum recommended size).

• A DVD drive is required for the program installation.

15
• Graphics adapter: Graphics card compatible with the supported operating systems, capable of

supporting 1024x768 High Color (16-bit), and a 17-inch monitor compatible with this type of

graphics card.

Getting Started With ANSYS:

There are two modes to run the ANSYS program: Interactive mode and Batch mode.

• Interactive Mode

This is the default mode in ANSYS. It allows you to work with menus and dialog boxes

(Graphical User Interface), online help, and tools to create models in the graphics window.

• Batch Mode

In the batch mode, you can execute a file of commands in the ANSYS program. It is useful when

you do not want to interact with the program such as during the solution phase of an analysis.

Simulation Environment

This drop-down Hst is used to specify whether you want to run the interactive or the batch

interface. The options available in this drop-down list are:

• ANSYS Workbench

• ANSYS

• ANSYS Batch

• MFX - ANSYS/CFX

• LS-DYNA Solver

Types of Analysis

The following types of analysis can be performed in ANSYS software:

1. Structural analysis

16
2. Thermal analysis

3. Fluid flow analysis

4. Electromagnetic field analysis

5. Coupled field analysis

Structural Analysis

In structural analysis, first the nodal degrees offi-eedom(displacement) are calculated and then

the stress, strains, and reaction forces are calculated fi'om the nodal displacements.

Static Analysis

In static analysis, the load or field conditions do not vary with respect to time and therefore, it is

assxmied that the load or field conditions are applied gradually, not suddenly. The system imder

analysis can be linear or nonlinear. Inertia and damping effects are ignored in structural analysis.

In structural analysis, the following matrices are solved:

[K]x[X]=[F]

Where,

K = Stif&iess Matrix

X = Displacement Matrix

F = Load Matrix

The above equation is called the force balance equation for the linear system. If the elements of

matrix [K] are a function of [X], the system is known as a nonlinear system. Nonlinear systems

include large deformation, plasticity, creep and so on. The loadings that can be applied in a static

analysis include:

1. Externally applied forces and pressures

17
2. Steady-state inertial forces (such as gravity or rotational velocity)

3. Imposed (non-zero) displacements

4. Temperatures (for thermal strain)

5. Fluences (for nuclear swelling)

The outputs that can be expectedfroma FEA software given next.

1. Displacements

2. Strains

3. Stresses

4. Reaction forces

Dynamic Analysis

In dynamic analysis, the load orfieldconditions do vary with time. The assumption here is that

the load or field conditions are applied suddenly. The system can be linear or nonlinear. The

dynamic load includes oscillating loads, impacts, colUsions, and random loads. The dynamic

analysis is classified into the following three main categories:

Model Analysis

It is used to calculate the naturalfrequencyand mode shape of a structure.

Harmonic Analysis

It is used to calculate the response of the structure to harmonically time varying loads.

18
 CHAPTER 4

COMPUTER AIDED DESIGN AND METHODOLOGY

4.1 COMPUTER AIDED DESIGN

Computers are sophisticated tools that are used in every facet of society to provide accuracy,

flexibility, cost-saving, efficiency, record keeping, and vast storage, decision making tools and

modeling. The use of computers to design two or three dimensional models of physical objects is

known as computer aided design. Computer aided design is use of computer to aid in the design

and especially the drafting of a part or product. It is both a visual and symbol based method of

communications whose conventions are particular to a specific technical field. Designers in

architecture, electronics, aerospace and automotive engineering, for example, use Computer

aided design systems and software's to prepare drawings and specifications that once could only

be drawn or written by hand.

Before CAD, manufactures and designers would have to build prototypes of automobiles,

buildings, computer chips, and other products before the prototypes could be tested. CAD

technology, however, allows users to rapidly produce a computer generated prototype and then

test and analyze the prototype imder a variety of simulated conditions. Current CAD software

packages rangefi-om2D vector base drafting system to 3D solid and surface modelers. Modem

CAD packages can also frequently allow rotations in three dimensions, allowing viewing of a

designed objectfi-omany designed angle, evenfi"omthe inside looking out.

Manufacturers and designers also use CAD technology to study optimization, performance, and

reliability problems in prototypes and in ah-eady exiting designs. Drawing can be modified and

enhanced imtil the desired results are achieved. CAD is very usefiil for prototyping because it all

allows designers to see problems before times and money is invested in an actual product.

19
Computer-aided design (CAD) is a form of automation that helps designers prepare drawings,

speciation, parts lists, and other design-related elements using special graphic- and calculation-

intensive computer program. Although CAD system was merely automated drafting, they now

usually include three-dimensional modeling and computer-simulated operation of the model.

Rather than having to build prototypes and change components to determine the effect of

tolerance range, we can use computer to simulate operation to determine loads and stresses for

example, an automobile manufacture might use CAD to calculate the wind drag on several new

car-body designs without having to build physical models of each one.

4.1.1 BASICS OF CAD SYSTEMS

Architectural renderings and drawings can be modeled on computers as searching, selects, and

computational task. Searching task is represented as sets of variables with acceptable values.

The design software selects alternatives using a generate-and-test process. Design also takes the

form of optimization. In these Instances rigid structural limits are imposed within a narrow

design space. Computations are performed to predict performance and redesign possible

solutions. Searching, selecting, and optimizing are iterative, but compilation is not. Compilation

uses programmed algorithms to translate facets of a problem into machine language and arrive at

a workable solution.

Niraierical fimctions that are the basis for mathematical models are at the heart of CAD tasks.

Mathematical models define the basic building blocks of 3-D models. Points, curves, and lines

are just a few of the predefined elements that are manipulated geometrically in CAD Systems.

Points are usually represented by either two or three values depending on whether a 2-D or 3-D

model is being used. Curves are one-dimensional entities that smoothly connect moving points.

20
Lines are entities that have xmiform endpoints. Many other geometrical models are used in CAD

system they represent circles, arcs, different types of curves, polygons, and other fundamental

entities that are used to construct images. Displaying 3D objects after mathematical modeling

develops a rendering of a computer image, it is stored and displayed.

4.1.2 SOFTWARE TECHNOLOGIES

Originally software for CAD system was developed with computer language such as

FORTRON, but with the advancement of object-oriented programming methods this has

radically changed. A CAD system can be seen as buih upfromthe interaction of a graphical user

interface (GUI) with NURBS geometry and/or boundary representation (B-rep) data via a

geometrical modeling kernel. A geometry constraint engine may also be employed to manage the

associative relationship between geometry, such as wire-frame geometry in a sketch or

components in an assembly.

Unexpected capabilities of these associative relationships have led to a new form of prototyping,

caked digital prototyping. In contrast to physical prototypes, which entail manufacturing time

and material costs, digital prototypes allow for design verification and testing on screen,

speeding time to market and decreasing costs.

4.1.3 fflSTORY

Designers have used computers for their calculations since long time. Initial developments were

carried out in the 1960s within the aircraft and automotive industries in the area of 3D surface

construction and NC Programming, most of it independent of one another and often not

publically published until much later. However, probably the most important work on

21
polynomial curves and sculptured surface .was done by Pierre Bezier (Renault), Paul de

Casteljau (Citroen), Steven Anson Coons (MIT, FORD), James Fergusan (Boeing), Carl De Boor

(GM), Birkhoff (GM) Garibedian (GM), in the 1960s and W. Gordan (GM) and R. Riesenfeld in

the 1970s.

Key products 1981 were the solid modeling packages - Romulus (Shapedata) and Uni-solid

(Unigr^hics) based on PADL-2 and release of the surface modeler CATIA (Dassault systems).

Autodesk was founded 1982 by John Walker, which led to the 2D system Auto Cad. The next

milestone was the release of Pro-Engineer in 198 8, which heralded greater usage of feature, based

modeling methods and parametric linking of the parameters of features. Also of importance to

the development of CAD was the development of the B-rep soiled modeling kernel at the end of

the 1980s and beginning of the 1990, both inspired by the work of Ian Braid. This Led to the

release of mid-range packages such as Solid Works in 199, solid Edge (Intergraph) in 1996, Iron

CAD in 1998, and Autodesk Inventor in 1999. Today CAD is one of the main tools used in

designing product and architecture and also in the field of engineering because of cutting edge

technologies that have come out in the last few years.

4.1.4 FUTURE DIRECTION FOR CAD

Virtual Reality (VR) is a 3-D visualization tool that is used to construct buildings, manipulate

object in real-time, and build prototypes. Certain features of virtual reality are likely to appear in

future CAD packages once standards and protocols are developed. This scenario is desirable to

reduce the duplicity involved in transferring geometric data between CAD and VR system.

Future development in CAD system might also yield more sophisticated systems for building

complex, irregular forms. Such a development along with rapid prototyping, combination of VR

22
visualization techniques, and artificial intelligence (AI) might take CAD systems more

responsive and more powerful development tools in manufacturing, design and engineering

environments.

Other advances in CAD technology might involve sharable web based design libraries and

widespread use of agent based approaches, the computer system would function like a

knowledgeable partner that would work collaboratively to solve problem and address concerns.

The agent would be a type of knowledge base that would store information and model planning

and integration activities.

Distributed AI application may be the main focus of the next generation of CAD tools because

of their ability to codify and represent knowledge structures. These complex systems have the

ability to "learn" or change their rule sets based on inconsistencies, inaccuracies, and incomplete

data. Applying learning to CAD applications may help reduce the problems of planning and

system malfunctions due to the introduction of inaccurate and incorrect data.

4.1.5 CAPABILITIES
The capabilities of modem CAD systems include:

• Wire frame Geometry creation

• 3D Parametric feature based modeling, solid modeling

• Freeform surface modeling

• Automated design of subassemblies and assembly

• Create engineering drawings from the solid models

• Ease of modification of design of model

• Automatic generation of standard components of the design

23
 Validation of designs against specification and design rule

Simulation of designs without building a physical prototype

Manufacturing drawings and bills of materials

Import/export or exchange of data with other software packages

Output of design data directly to manufacturing facilities

Rapid prototyping of machine for industrial prototypes

Maintain libraries of parts and assemblies

Calculate mass properties of parts and assemblies

Aid visualization with shading, rotating, hidden line removal, etc

Bi-directional parametric association (modification of any feature is reflected in all

information relaying on that feature; drawing, mass properties, assemblies, etc.

Kinematics, interference and clearance checking of assemblies.

Sheet metal

House/cable routing

Electrical components packing

Inclusion of programming code in a model to control and relate desired attributes

of the model

Programmable design studies and optimization

4.1.6 USES

CAD is used to design, develop and optimize product, which can be goods used by end consumer

or intermediate goods used in other product. CAD is also extensively used in the design of tools

and machinery used in the manufacture of components, and in the drafting and design of all

24
types of buildings, from small residential types (house) to the largest commercial and industrial

structures (hospital and factories).

CAD is mainly for detailed engineering of 3D models and/or 2D drawings of physical

components, but it is also used throughout the engineering process from conceptual design and

layout of products, through sfrength and dynamic analysis of assemblies to definition of

manufacturing methods of components.

CAD has become an especially important technology, within the scope of computer aided

technologies, with benefits such as lower product development costs and a greatly shortened

design cycle. CAD enables designers to layout and developers work on screen, print it out and

save it for future editing, saving time on their drawings.

4.1.7 APPLICATION AREA

The Architecture, Engineering and construction (AEC) Industry

Architecture

Architectural Engineering

Interior Design

Interior Architecture

Building Engineering

Civil Engineering and Infrastructure

Construction

Roads and Highways

Raihoads and Tunnels

Water supply and HydrauUc Engineering

25
 • Storm Drain, Waste water and Sewer system

• Mapping & Surveying

Plant Design

• Factory Layout

• Heating, Ventilation and Air-Conditioning (HVAC)

Mechanical Engineering (MCAD)

• Automotive Vehicles

• Aerospace

• Consumer goods

• Machinery

• Shipbuilding

• Bio-mechanical systems

26
 CHAPTER 5

FINITE ELEMENT ANALYSIS (FEA/FEM)

5.1 INTRODUCTION

The finite element method is a numerical method for solving engineering and mathematical

physics problems. The typical use of this method is to solve the problems in the field of stress

analysis, heat transfer, fluid flow, and mass transfer and electromagnetic. This method can able

to solve physical problems involving complicated geometries, loadings and material properties

which cannot be solved by analytical method. In this method, the domain in which the analysis to

be carried out is divided into smaller bodies or unit called as finite elements.

The properties of each type of finite element is obtained and assembled together and solved as

whole to get solution. Based on application, the problems are classified into structural and non-

structural problems. Finite Element Analysis (or other nimierical analysis), development of

structures must be based on hand calculations only. For complex structures, the simplifying

assimiptions required to make any calculations possible can lead to a conservative and heavy

design. A considerable factor of ignorance can remain as to whether the structure will be

adequate for all design loads. In structural problems, displacement at each nodal point is

obtained. Using these displacement solutions, stress and strain in each element are determined.

Similarly, the non-structural problems, a temperature or fluid property at each nodal point is/are

obtained. Using these nodal values, properties like heat flux, fluid flow etc., for each element is

determined. Since large computations are to be carried out, this method requires high-speed

computation facility with large memory. Finite element method (FEM) and finite element

analysis (FEA) are both one and same term. But term FEA is more popular in industries while

FEM is famous at universities.

27
5.2 BRIEF HISTORY

The finite element method used today was developed to its present state very recently. According

to Zinckiewicz, the development is occurred along two major paths, one in mathematics and

other in engineering; somewhere in between these two paths are variational and weighted

residual methods. Both of which requires trial functions to effect a solution. The use of these

functions data is sent back to almost 250 years. These trial functions are ass\mied based on

physical intuition and they are applied globally to

get the solution for the problem. The use of trial functions is neither considered as development

in pure mathematical field nor in engineering field.

In a paper by Gauss in 1795, trial functions were used in what is now called as the method of

weighted residuals. Later, Rayleigh used these functions in variational method in 1870 and by

Ritz in 1909. In a landmark paper in 1915; Galerkin introduced a particular type of weighted

residual method which is called by his name as "Galerkin weighted residual method".

In 1943, Courant introduced piecewise trial functions which are now called as shape functions.

These shape fimctions are applied in a smaller region (i.e. at element level) instead of applying it

globally which is made him to solve the real world problems. In the early 1940's, aircraft

engineers were developing and using analysis method called force matrix method which is

recognized as early form of finite element method. In this method, the nodal imknowns are

forces not the displacements. When the displacements of each node are taken as unknown, the

method is called as "St Method".

In a paper in 1960, Clough first introduced the term "Finite element". In 1965, Zinekiwicz and

Cheung applied FEM, to solve the non-structural problems. Szabo & Leo showed how the

28
weighted residual method, particularly the Galerkin method could be used in non-structural

problem analysis. However, the present day FEM does not have its roots in any discipline.

Mathematicians are trying to improve the mathematical backgroimd of FEM, while the engineers

are interesting in applications where FEM can be used. In most branches of engineering, these

developments have made the FEM as one of the most powerful numerical solution method.

5.3 FINITE ELEMENT METHOD (FEM)

Finite Element method (FEM) simulates a physical part or assembly's behavior by dividing the

geometry of the part into a number of elements of standard shapes, applying loads and

constraints, then calculating variables of interest - deflection, stresses, temperature, pressures

etc. The behavior of an individual element is usually described by a relatively simple set of

equations. Just as the set of elements would be joined together to build the whole structure, the

equation describing the behaviors of the individuals elements are joined into a set of equations

that describe the behaviors of the whole structure.

FEM is:

- A numerical method
II

- Mathematical representation of actual problem

- Approximate method

Definition of FEM is hidden in the world itself Basic theme is to make calculation at only

limited number of points and then interpolate the result for entire domain (surface & volume).

29
Finite- any continuous object hasfinitedegree offi-eedom& it's just not possible to solve in this

fonnat. Finite Element Method reduces degree of freedom from infinite tofinitewith the help of

discretization i.e. (nodes & elements).

Element- all the calculations are made at limited niraiber of points known as nodes. Entity

joining nodes and forming a specific shape such as quadrilateral or triangular etc. is known as

Element. To get value of variable (say displacement) at where between the calculation points,

interpolation function (as per the shape of element) is used.

Method- There are three methods to solve any engineering problem. Finite Element Analysis

belongs to numerical method category.

A Finite Element program takes the elements you have defined, lists the equations for each

imknown value, puts them together as a matrix equation, and then solves all these for the values

of the unknown parameters.

The equilibrium equation is of the form:

[K] [u] = [f]

Since it's analogous to the equations of spring deflection, K is often called stif&iess matrix, u is

called the deformation vector, and f is called the load vector. K is a square matrix, with one row

and column for each unknown variable in the problem definition. If there are 100 nodes in a

model, and each node has 6 unknowns, then stiffness matrix would be 600 X 600. u and f are

each colimm-matrix which has 1 column and 600 rows.

30
5.4 FINITE DIFFERENCE METHOD (FDM)

In this approach, there are no elements - the discrete points are referred to as grid points or grids

some analyses program call for "Structured " grids the numbering of and positioning of grid

points must follow specific patterns. Other analyses programs are less stringent in their

requirements imstructured grids or blocks are supported. It is used influidflowanalysis.

5.5 COMPARISON OF FEM AND FDM

The major difference between FEM and FDM are:

• The most altercative feature offinitedifference is that it can be very easy to implement.

• There are reasons to consider the mathematical foundation of the finite element

approximation more sound, for instance, because the quality of the approximation

between grid points is poor in FDM.

• The quality of a FEM approximation is often higher than in the corresponding FDM

approach, but this is extremely problem dependent and several examples to the contrary

can be provided.

31
5.6 PROCEDURE OF FEM

The following steps summarize the finite element procedure:

Steps Phases

Discretization
-> Preprocessing

Numbering Nodes and

Element

Selection Displacement or
Interpolation Model

Defining material behavior

Derivation of element
equation •> Analysis

Assembling

Applying Boundary
Conditions

Solution

Obtaining Required Results

-> Postprocessing
from solution

Fig - 5.1 Procedure of FEM

32
5.7 PRACTICAL FEM THROUGH FEA SOFTWARES/FEA TOOLS

In FEA software, the general process offiniteelement method is divided into three main phases:

preprocessing, solution, and post processing. There are a nimiber of softwares used for these

three phases. Some softwares such as ANSYS and ABAQUS are used for all the three phases

and some softwares use different softwares for these three phases, e.g in Altair Hyperworks 9.0,

Hypermesh 9.0 which is one of the best pre processing tool is used as Pre Processor and

Otpsitruct/RADIOSS are used as Solvers and dien after solution Hypermesh and HyperView are

used for Post Processing.

Similarly for solution in MSC Nastran, MSC Patran is used as pre processor and Post processor.

In Femap with Nx Nastran, Femap is used as Pre- processor and Post-processor and Nx Nastran

is used as Solver.

• Preprocessing

The preprocessing is a program that processes the input data to produce the output that is used as

input to the subsequent phase (solution).Here ansysll is used as a Pre-Processor. Following are

the input data that needs to be given to the preprocessor:

1. Type of analysis (structural or thermal, static or dynamic, and linear or nonlinear)

2. Element type.

3. Real constraints.

4. Material properties.

5. Geometric model.

6. Meshed model.

7. Loadings and boundary conditions.

33
The input data will be preprocessed for the output data and preprocessor will generate the data

files automatically with the help of users. These data files will be used by the subsequent phase.

• Solution

Solution phase is completely automatic. The FEA software generates the element matrices,

computes nodal values and derivatives, and stores the result data in files. These files are fiirther

used by the subsequent phase as for this purpose (postprocessor) to review and analyze the

results through ihe graphic display and tabular listings.

• Post processing

The output firom the solution phase (result data files) is in the numerical form and consists of

nodal values of the field variable and its derivatives. For example, in structural analysis, the

output is nodal displacement and stress in the elements. The postprocessor processes the result

data and displays them in graphical form to check or analyze the result. The graphical output

gives the detailed information about the required result data. The postprocessor phase is

automatic and generates the graphical output in the form specified by the user. Result Viewer

and Plot Result are used for Post-Processing in his problem.

5.8 KEY ASSUMPTIONS IN FEA

There are four basic assumptions that affect the quality of the solution and must be considered

for finite element analysis. These assumptions are not comprehensive, but cover a wide variety

of situations applicable to the problem. Moreover, by no means, do all the following assumptions

apply to all the situations. So, make sure to use only those assumptions that apply to the analysis

imder consideration.

• .Assumptions Related to Geometry

34
1. Displacement values will be small so that a linear solution is valid.

2. Stress behavior outside the area of interest is not important, so the geometric simplifications

in those areas will not affect the outcome.

3. Only internal fillets in the area of interest will be included in the solution.

4. Local behavior at the comers, joints, and intersection of geometries is of primary interest;

therefore no special modeling of these areas is required.

5. Decorative external features will be assimied insignificant for the stifi&iess and

Performance of the part and will be omittedfi-omthe model.

6. The variation in mass due to the suppressed features is negligible.

• Assumptions Related to Material Properties

1. Material properties will remain in the linear region and nonlinear behavior of the material

property cannot be accepted. For example, it is understood that either the stress levels exceeding

the yield point or excessive displacement will cause a component failure,

2. Material properties are not affected by the load rate.

3. The component isfi*eefromsurface imperfections that can produce stress risers.

4. All simulations will assume room temperature, unless otherwise specified.

5. The effects of relative humidity or water absorption on material used will be neglected.

6. No compensation will be made to accoxmt for the effect of chemicals, corrosives, wears or

other factors that may have an impact on the long term structural integrity.

• Assumptions Related to Boundary Conditions

1. Displacements will be small so that the magnitude, orientation, and distribution of the load

remain constant throughout the process of deformation.

2. Frictional loss in the system is considered to be negligible.

35
3. All interfacing components will be assumed rigid.

4. The portion of the stracture being studied is assumed a separate part from the rest of the

system, therefore so that any reaction or inputfromthe adjacent features is neglected.

5.9 SOURCES OF ERRORS IN FEA

1. The model contains fundamental flaws: parts missing not connected, or details are

inappropriate.

2. The model may not properly represent the structure as built, or recorded in the engineering

drawings.

3. The loads or boundary conditions may not represent properly.

4. Failure to consider that a particular type of analysis was needed.

5. Experience of the analyst inappropriate to the task at hand plus inadequate errors in applying

design codes.

6. Computer is too small and slow to usefinemeshing, run nonlinear analysis, and review results

in sufficient detail.

5.10 ADVANTAGES AND DISADVANTAGES OF FEA

Advantages of FEM:

1. Irregular geometries can be modeled more accurately and easily.

2. Implementation of any type of boimdary conditions is very easy.

3. With very little effort, heterogeneous and anisotropic materials can be modeled.

4. Any type of loading can be handled.

36
5. The element sizes can be varied throughout the model. Wherever it is necessary. We can use

fme meshes.

6. Whether the problem is linear or non linear, the basics (i.e. steps followed/implemented) of

FEA remain same.

7. Altering the element model with different loads, boundary conditions and other changes on

the model can be done easily.

Disadvantages:

1. FEA softwares are costlier.

2. Output result will vary considerably, when the body is modeled with fine mesh when

compared to body modeled with course mesh.

3. Before using a element for a problem, we should know about its capabilities and nature,

because no single element is available for all applications.

4. Even though the FEA softwares are userfiiendlybut they are not relatively easier for use.

5.11 APPLICATIONS OF FEA

The FEA can be used to analyze both the structural and non-structural problems,

(a) Types of structural problems,

(i) Stress analysis

a). Linear Analysis

37
 Software follows this path for
Linear static calculation

Stress Actual stress-strain curve

Strain

Fig 5.2 Linear Analysis

Example: Linear Analysis: - Plate with hole subjected to plane loads.

Commonly used softwares: Nastran, Ansys, Abaqus, I-deas NX, Radioss, Cosmos, UG, Pro-

Mechanica, Catia etc.

b). Non-linear analysis:-

Non-Linearity

Geometrical Material Contact

Large Gap elements &

Deformation contact simulation

Beyond Elastic Limit 'E' Within Elastic Limit 'E' Creep

metals 'Non metals' (Progressive) deformation of
material at constant stress.
Long time process

Fig. 5.3 Non Linearity Analysis

38
Material Non-linearity - Machine element members are subjected to stress more than elastic

limit.

Within E (non-metal) Beyond E (metals)

Linear •<-j-^ Non-Linear

Stress Stress

Strain Strain

Fig 5.4 Material Non-Linearity

Geometrical non-linearity: - Thin shell structure is subjected axial loads or Torque. Though

component is within the elastic limit but due to very large length even small force causes large

deformation. Both material and geometrical non-linearity: - Thin shell structures are subjected to

mechanical loading with high temperature creep effect. Commonly used softwares: Abaqus,

Nastran, Ansys, Marc, Radioss, LS Dyna etc

(ii) Eigen Buckling Analysis: Example: Connecting rod subjected to axial compression. This

analysis can be used to determine mode shape of buckling load and its critical loads. Commonly

used softwares: Nastran, Ansys, Abaqus

39
(iii) Dynamic Analysis:

Dynamic Analysis

Free
r ]
Forced

i
Natural frequency
i
Response to the External excitation

The frequency with

which any object will
vibrate if disturbed &
allowed to vibrate on Frequency response Transient response Random Vibrations
its own without any
external force. Frequency domain, Time domain, Arbitrary Random nature of
(On=Vk/m steady state sinusoidal but well define loading, usually input
excitation limited to excitation Constant in the form of PSD
linear elastic structures acceleration or force at (Power Spectral
Rotating machinery, a given frequency, Density)
unbalanced tyres Road excitations etc.
Helicopter blade

Fig 5.5 Types of Dynamic Analysis

IMU? + [ClX + lK]X = F(t)

Example: Beams subjected to different types of loading. This analysis can be used to determine

the mode shape of vibration with its natural frequencies.

Commonly used softwares: Nastran, Ansys, Abaqus, Matlab, I-deas NX, Radioss etc.

(b) Types of non-structural problems

(i) Heat Transfer Analysis:

Thermal Analysis

40
 Modes of Heat Transfer

t
Conduction Conv<;ction Radiation
1
\\ \[
Stesidy State Unstejidy State Natural •> Specular
Condiction Conduction " Convection

—•l-D —•l-D
—•2-D —•2-D ^ Forced -•Diffuse
'—•S-D • 3-D Convection
Fig 5.6 Modes of heat transfer analysis

Linear: - Steady state thermal analysis on composite wall.

Non-linear:- Thermal Analysis with anisotropic materials.

The heat transfer problem can be further classified as Steady state (time independent) and

Transient (time dependent)

Practical applications: Engine, radiator, exhaust system, heat exchangers, power plants, satellite

design etc. Commonly used softwares: Ansys, Nastran, Abaqus, I-deas NX etc.

(ii) Fluid-flow Analysis:

Computational Fluid Dynamics (CFD) is a branch of Fluid mechanics which uses Numerical

Methods to analyze fluid dynamics problems. It is based on Navies-Strokes equation (Mass

Momentum and Energy conservation equations)

Example: Fluid flow through pipes or channel.

(iii) Electromagnetic Analysis:

Example: Modeling of electromagnetic field of motor.

41
Recently FEM is used in Bio-Mechanical Engineering field. For example, stress analysis on

human parts like bones, joints, skull, tooth etc.

(iv) Fatigue Analysis

Calculations for Ufe of the structure when subjected to repetitive load.

S- N curve (alternating stress vs. cycles) or E - N (alternating strain vs. reversals) is the base for

fatigue calculations.

Low cycle
fatigue High cycle fatigue

Alternating
Stress

10^ 2*10^ No. of Cycles

Fig 5.7 - Stress and Number of cycle Curve for fatigue analysis

(v) Noise Vibration and Harshness Analysis (NVH)

Practical applications: Computing the sound pressure levels is of utmost importance to

automobile, aeroplane and aerospace designers as customers always prefer a low noise level

Computing the response at the driver's feet (brake pedal), mirror mounts, steering column and

seats plays a crucial role as the driver must be comfortable.

Commonly used softwares: Sysnoise, LMS - Virtual Lab, Matlab etc.

42
 CHAPTER 6
FE MODELING METHODOLOGY AND ANALYSIS

6.1 ANSYS

6.1.1 Introduction
ANSYS is a general purpose finite element modeling package for numerically solving a wide

variety of mechanical problems. These problems include: static/dynamic structural analysis (both

linear and non-linear), heat transfer and fluid problems, as well as acoustic and electro-magnetic

problems.

The procedure for FE analysis consists of three main steps

1. Pre-processing

2. Solver

3. Post Processing

This is a general guideline that can be used for setting up any finite element analysis.

6.2 STATIC ANALYSIS

Static analysis is used to determine the displacements stresses, strains and forces in structures or

components due to loads that do not induce significant inertia and damping effects. Steady

loading in response conditions are assumed. The kinds of loading that can be applied in a static

analysis include externally applied forces and pressures, steady state inertial forces such as

gravity or rotational velocity, imposed (non-zero) displacements, temperatures (for thermal

strain).

43
6.2.1 OVERVIEW TO THE PROBLEM
The front axle of fann tractor is ma<te of alloy steel and acts like a simply supported beam. The

parameters of axle are: Length= 1120mm, width = 50 mm and height = 100 mm. Cross-section

of axle is rectangular having the thickness of plate 6 mm. As the axle is subjected to static

loading and dynamic loading, so the structural and modal analyses of a front axle are of great

importjuice to determine whetiier a front axle can withstand all the forces acted from the

surrounding. Structural and modal analyses are carried out for analyzing the stability of the

structure mid for finding out the deflection. The proposed 3-Dimensional model of front axle is

shown in fig.6.1

^yfm

Fig. 6.1 Geometric model offix)ntaxle

44
 The design parameters of Front axle of Farm Tractor are given as in Table-6.1 below:
i
Parameter Value
Material selected- steel St 37-2
Young's Modulus, E 2.0* 10' MPa
Poisson's Ratio 0.30
Tensile strength Ultimate 340 MPa
Tensile strength Yield 235 MPa
Compressive yield strength 235 MPa
Volume 2.1069*10^ mm='
Mass 16.855 kg
Normal Static loading 35000 N
Density 8000 kg/m3
Behavior Isotropic
Nodes 25956
Element 12959

Table-6.1 Parameters of St 37-2 Front Axle

\
6.2.2 MATERIAL PROPERTIES

Young's modulus (EX) must be defined for a linear static analysis. If we plan to apply inertia

loads (such as gravity) we define mass properties such as density (DENS). Similarly if we plan

to apply thermal loads (temperatures) we define coefficient of thermal expansion (ALPX).The

material properties is chosen as per the given specification

6.2.3 MESH GENERATION

In the finite element analysis the basic concept is to analyze the structure, which is an

assemblage of discrete pieces called elements, which are connected, together at a finite number

45
of points called Nodes. Loading boundary conditions are tlien applied to these elements and

nodes. A network of these elements is known as Mesh. Meshing is the process in which your

geometry is spatially discretized into elements and nodes. This mesh along with material

properties is used to mathematically represent the stifKhess and mass distribution of your

structure. The default element size is determined based on a number of factors including the

overall model size, the proximity of other topologies, body curvature, and the complexity of the

feature. Meshed model is shown in Fig.6.3

V^
Fig.6.2: 3-D Mesh Model

6.2.5 APPLIED CONDITIONS AND LOADING:

After completion of the finite element model, boundary condition and loads are applied. User can

define constraints and loads in various ways. All constraints and loads are assigned set ID. This

46
helps the user to keep track of load cases. The boundary condition is the collection of different

forces, pressure, velocity, supports, constraints and any other condition required for complete

analysis. Applying boundary condition is one of the most typical processes of analysis. A special

care is required while assigning loads and constraints to the elements. A static Load of 35000 N

is applied on the axle; the graph for static load is shown in fig.6.3

-5000.-

-10000

-15000-

-20000-

-25000

-30000-

-35000

Fig.6.3 Static Load

Two Cylindrical supports are given to thefrontaxle considering it as a simple beam. And the

load is applied in the center offrontaxle. The whole problem becomes as simple as the simply

supported beam having the concentrated load at the center of beam. The applied conditions on

the Front axle are shown in the Fig-6.4 on next page

47
 #MisysA
!S^a@Bit m4{iAM
CyAKirieaf Si^sport; O. mm
i C^feMtricat Suftport 2: O. mm
I Force: 36Q00 N

I Ftg.6.4 Applied constraints on the front axle

6.2.6 MODEL DISPLAY:

While applying the boundary conditions, it is necessary to view the model from different angles

Pre processor offers capabilities of rotating, smoothness, scaling, and regions, active set, etc for

efficient model viewing and editing.

6.2.7 SOLUTION:

The solution phase deals with the solution of the problem according to the problem definitions.

All the tedious work of formulating and assembling of matrices are done by the computer and

finally displacements and stress values are given as output.

48
6.2.8 POST- PROCESSOR:
It is a powerful user- friendly post- processing program using interactive colour graphics. It has

extensive plotting features for displaying the results obtained from the finite element analysis.

One picture of the analysis results (i.e. the results in a visual form) can often reveal in seconds

what would take an engineer hour to assess from a nvmierical output, say in tabular form. The

engineer may also see the important aspects of the resxilts that could be easily missed in a stack

of numerical data. The entire range of post processing options of different types of analysis can

be accessed through the command/menu mode there by giving the user added flexibility

convenience

Employing state of art image enhancement techniques, facilities viewing of:

D Contours of stresses, displacements, temperatures, etc.

D Deform geometric plots

D Animated deformed shapes

D Time-history plots

D Solid sectioning

D Hidden line plot

D Light soiu'ce shaded plot

D Boimdary line plot etc.

49
 CHAPTER 7

RESULT AND DISCUSSIONS

The FEA result of the front axle have been analyzed and compared with the available

experimental results for validation. The Fig. 7.1 shows the von-mises stress contour of the front

axle for a load of 35000 N. The maximum stress is found to be (188.71 MPA) near the

cylindrical support. The value of maximum stress is well below the yield stress for the St 37-2

(type of alloy steel).

7.1 STATIC STRUCTURAL ANALYSIS RESULTS OF FONT AXLE OF

FARM TRACTOR

Fig. 7.1 and Fig. 7.2 show the stresses in the front axle. The color shown in the front axle

represents the stresses and deformation present in the element. Red color shows the maximum

stress & maximum deformation and Blue color shows the minimum stress and minimum

deformation in the respective figures.

rfMBVSI

SOaiOmt 9:40 AM

u
Fig. 7.1 Equivalent (Von-Mises) Stress for each element in the front axle.

50
 «*IH»^
rigpM»2
tMBvMNMM) ^ » « S S
Vnti MPs
Tan*: 1
SOaOOH 9.40 AM

t67-79
146.B7
125.95
106.04
84 117
63.198
42.279
21.36
0.44078 Min

L!.
Fig.7.2 Equivalent (Von-Mises) Stress for each element in the front axle.

UtifcoafB
TIHW: f

f . i s m Max
1.QQ5
0,^938
0.75375
0.62813
0.5C325
0 37688
0.2512S £"<•"* ,i.^s;;s;a
0.12563
0 Mfn
I

k.
Fig. 7.2 Total Deformation for each element in the front axle

51
 saaao^^'^ 9:«} A M

-I .DOS
0.87936
0.75375
0.62813
0.5025
Q. 3 7 ^ 3 8
0.25125
Q.125B3
0 Min

tl.
Fig. 7.3 Total Deformation for eacli element in the thjnt axle.

The Fig.7^ & 7 J shows the deformation contour for the same CAD model under similar loading

ccmditions. The maximum displacement is found to be 1.1306 mm which is negligible.

7.2 COMPARISON OF FEA RESULTS OF PRESENT MODEL

Sr.No. Parameters Experimental Results FEA Results of model

1 Von Mises Stress 180Mpa 188.71Mpa (Under permissible limit)

2 Displacement 2.1 mm
1.1306mm
Table No: 7.1 Resiilt Conrpariscms

The FEA results are in close agreement with the experimental results. The variation in the von-

mises stress is 4.8% which is negligible while the Deformation (deflection) in the front axle

should be less up to possibility which is less than the experiment value and found to be 1.1306

mm for our front axle model

52
After thoroughly examining the FEA results the stresses and deformation in the designed model

is much below the allowable limit. The present design is acceptable and safe for fiirther dynamic

simulation.

53
 CHAPTER 8

CONCLUSION

8.1 CONCLUSION & DISCUSSION

An attempt has been made to perform the Finite Element Analysis of front axle. Finite Element

analysis of thefrontaxle of a farm tractor has been done using FEA tool ANSYS-vl2. The load

and deformation for the analysis has been taken from the paper presented on the different-

different model offrontaxle for a farm tractor. From the results obtainedfromFE analysis, many

discussions have been made and it will be concluded that the maximimi von-mises stress

observed in FE analysis of the Front axle is under permissible limit, for the load of 35000N. The

maximum deformation is 1.1306 mm which is negligible and harmless. Also the volume and

mass of the present model is less than the available experimental models. Mass of 4.65 Kg will

be saved per axle which will decrease the cost of manufacturing in the mass production. The

results obtained are well in agreement with the similar available experimental results. The model

presented here, is well safe and imder permissible limit of stresses.

8.2 SCOPE FOR FUTURE WORK

• Dynamic and fatigue Analysis can also be performed to find the fatigue life of

thefrontaxle.

• Thermal analysis can also be done tofindthe temperature distribution in thefrontaxle.

• The design of the front axle can be studied again to provide further solution to

increase the performance offrontaxle.

• And the weight of the front axle can be reduced to cut down the material cost for the

manufacturing company.

54
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56