PRESENTED BY V.GUNASEKARAN MODELING AND FEM ANALYSIS FOR GEAR PLATE HOUSING UNDER THE GUIDANCE OF Ms. S.SRIDEVI, M.E LECTURER DEPARTMENT OF MECHANICAL ENGINEERING BHARATHIYAR COLLEGE OF ENGINEERING & TECHNOLOGY KARAIKAL
ABSTRACT <ul><li>This project deals to reduce the weight of the gear plate housing from its </li></ul><ul><li>existing weight without changing the material properties and other </li></ul><ul><li>assembly components. </li></ul><ul><li>This gear plate assembly is used in Motor Pumps. </li></ul><ul><li>The load acting on the gear plate is 90 Kg. </li></ul><ul><li>With the newly designed gear plate the whole assembly should be able to </li></ul><ul><li>with stand the same load without any damage. </li></ul><ul><li>For modeling and analysis the tool used are Pro/E and ANSYS. </li></ul>
ABSTRACT <ul><li>Using Pro/E 2D Drawing of the components has to convert into 3D </li></ul><ul><li>model. </li></ul><ul><li>In the redesigning of the gear plate, it is going to be finding out the </li></ul><ul><li>possible ways to design the gear plate in such a way that to reduce </li></ul><ul><li>the material weight to the specified limit and also the whole </li></ul><ul><li>assembly should be in safer condition. </li></ul>
REQUIREMENTS FOR THE ANALYST The analyst needs certain requirements while designing and assembling the parts of the product. Those requirements are mentioned below. • Displacement at certain points • Stress distribution • Natural frequencies • Vibrations • Pressure, Velocity and temperature distribution • Crack growth, residual strength and fatigue life.
METHODS OF ENGINEERING ANALYSIS There are different approaches to achieve the requirements They are • Experimental methods • Analytical methods • Numerical methods or approximate methods
EXPERIMENTAL METHODS In this method, prototypes can be used. If we want to change the dimensions of the prototype, we have to disassemble the entire prototype and reassemble it and then testing should be carried out. It needs man power and materials. So it is time consuming and costly process.
ANALYTICAL METHODS In these methods, problems are expressed by mathematical differential equations. It gives quick and closed form solutions. It is used only for simple geometries and idealized support and loading conditions.
NUMERICAL METHODS Analytical solutions can be obtained only for certain simplified situations. For problems involving complex material properties and boundary conditions, the engineer prefers a numerical method that gives approximate but acceptable solutions.
FUNCTIONAL APPROXIMATION <ul><li>The classical methods such as Rayleigh-Ritz methods (variational approach) and Galerkin methods (weighted residual methods) are based on functional approximation but vary in their procedure for evaluating the unknown parameter. </li></ul><ul><li>Rayleigh-Ritz method is useful for solving complex structural problems, encountered in finite element analysis. Weighted residual is useful for solving non-structural problems. </li></ul>
FINITE DIFFERENCE METHOD (FDM) <ul><li>Finite difference method is useful for solving Heat transfer, fluid mechanics and structural mechanics problems. It is a general method. It is applicable to any phenomenon for which differential equation along with the boundary conditions is available. It works well for two dimensional regions with boundaries parallel to the coordinate axes. </li></ul>
FINITE ELEMENT ANALYSIS <ul><li>In this method, a body or a structure in which the analysis to be carried out is subdivided in to smaller elements of finite dimensions called finite elements. Then the body is considered as an assemblage of these elements connected at a finite number of joints called 'Nodes' or Nodal points. The properties of each type of finite element are obtained and assembled together and solved as a whole to get solution. </li></ul>
FINITE ELEMENT PROBLEMS Based on application, the finite element problems are classified as follows: • Structural problems. • Non-structural problems.
STRUCTURAL PROBLEMS <ul><li>In structural problems, displacement at each nodal point is obtained. By using these displacement solutions, stress and strain in each element can be calculated. </li></ul>NON STRUCTURAL - PROBLEMS <ul><li>In non-structural problems, temperature of fluid pressure at each nodal point is obtained. By using these values, properties such as heat flow fluid flow etc., for each element can be calculated. </li></ul>
GENERAL STEPS IN FEA <ul><li>Two general methods are associated with the finite element analysis. They are: </li></ul>• Force Method • Displacement or stiffness method. In force method, internal forces are considered as the unknowns of the problem. In displacement or stiffness method, displacements of the nodes are considered as the unknowns of the problems.
PART MODELING <ul><li>The Part Modeling helps to introduces the terminology, basic </li></ul><ul><li>design concepts, and procedures that must know before start </li></ul><ul><li>building a part. </li></ul><ul><li>Part Modeling shows how to draft a 2D conceptual layout, create </li></ul><ul><li>precise geometry using basic geometric entities, and dimension </li></ul><ul><li>and constrain part geometry. </li></ul>
PART MODELING Once we can learn how to build a 3D parametric part from a 2D sketch by combining basic and advanced features, such as extrusions, sweeps, cuts, holes, slots, and rounds. Finally, Part Modeling Help provides procedures for modifying part features and resolving failures.
MASS CALCULATIONS From the dimensions of gear plate housing the volume and mass were calculated Volume of the gear plate housing = 4.48xl0 6 m 3 Density of wrought iron = 770 kg/m 3 Weight of the gear plate housing = 3.45 kg Maximum Tensile stress for wrought iron = 4000 N/mm 2 Compressive stress for wrought iron = 2000 N/mm 2
ANSYS 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 nonlinear), heat transfer and fluid problems, as well as acoustic and electromagnetic problems .
STEPS INVOLVED IN ANSYS Preprocessor Lets the user build the model geometry and assign element types, geometric and material properties. Solution Lets the user select the type of analysis, apply the boundary conditions to the FE model and invoke the solution process of the FE equations.
GENERAL POSTPROCESSOR Lets the user view results obtained in the FE analysis for the entire model for static or study state analyses. It will also provide the instantaneous results at selected points in time for transient and dynamic
RESULT FOR THE EXSISTING MODEL The result has been calculated for the model. MODEL Weight- 3.45 kg Stress-1541 N/mm 2 It is clear from the results that the stress values are well with in the limits. So the design is under safer condition.
HYPER MESH <ul><li>Hyper Mesh is a high performance finite element pre and postprocessor that allows you to build finite element and finite difference models, view their results, and perform data analysis. </li></ul>
REMODELLING OF GEAR PLATE HOUSING <ul><li>The new remodel gear plate is modeled using PRO-E by chamfering the edges and removing the unwanted material in sides by shell and at the bottom of the gear plate. This was done by various stages of design and finally the product has reduced its weight. </li></ul>
RESULT <ul><li>The result has been compared for its stress and weight for both old and new model. </li></ul>OLD MODEL Weight- 3.45 kg Stress-1541 N/mm 2 NEW MODEL Weight- 2.77 kg Stress-1661 N/mm 2
CONCLUSION <ul><li>In the gear plate housing the material weight is reduced without changing the properties or material. Using Pro/E the gear plate has been newly designed by reducing unwanted material in the gear plate. A new model has been created and a mass property has been found out. It was less than the old model. </li></ul>
CONCLUSION <ul><li>Thus the weight has been reduced in the new model design and also it with stand the load acting on it. Stress distribution in the new modeled gear plate does not exceed the ultimate stress value of wrought iron. Hence the design in safe. The material reduction leads to reduce the product cost also. </li></ul>
SCOPE FOR THE FUTURE WORK <ul><li>The gear plate housing reduces the material weight without changing the properties or material. But we can also change the properties as well as the materials used for the Gear Plate Housing. Thus by changing the material properties we can able to get the results for various applications with some specific tasks. </li></ul>