mechanical

1. 1
STATIC AND DYNAMIC ANALYSIS OF AL-ALLOY-7075
COMPOSITE MATERIAL WITH DIFFERENT
MANUFACTURING SYSTEMS
ABSTRACT
The damping capacity of a material refers to its ability to convert mechanical vibration energy
into thermal energy or other energies. The damping capacity is very important to some materials,
especially the structural materials. It is well known that mechanical vibration causes much damage in
aerospace industry, automotive industry and architectural industry. So, it is urgent to seek for high
damping capacity materials to eliminate the damage. Since the specific gravity of Aluminium is
approximately 2.8g/cc, the composites of Aluminium play a very significant role in light weight
machine components. Silicon, copper, magnesium, iron, manganese, and zinc are important elements
in Aluminium composites.
The properties of these alloys can be prepared and these readily can be used in design
engineering with the instructions for other alloys. In the present study an analysis tool finite element
analysis (FEA) will be used. The work presented in this paper is aimed at the study of effect of
vibration characteristics of aluminium alloys of different compositions. The modelling and analysis
will be carried out using ANSYS software. A modal analysis will be carried out to understand the
vibration behaviour i.e., natural frequency and mode shapes, of the material considered. The mode
shapes and natural frequency play an important role in the design of dynamic machines. Finally we
conclude by static and dynamic load conditions which material is having good strength to weight
ratio.
After completion all these design and analysis then we have to manufacture our object
and each material has its own physical properties. According to their properties we have to most
suitable process. In this process here we also discuss different manufacturing systems according to
the results of design and analysis.
Tools were used:
Cad tool: creo-2
Cae tool: Ansys workbench

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CHAPTER-1
1. INTRODUCTION
Aluminium (in Common wealth English) or aluminium (in American English) is
a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery-
white, soft, nonmagnetic, ductile metal. Aluminium is the third most abundant element in the
Earth's crust (after oxygen and silicon) and its most abundant metal. Aluminium makes up about
8% of the crust by mass, though it is less common in the mantle below. Aluminium metal is so
chemically reactive that native specimens are rare and limited to extreme reducing environments.
Instead, it is found combined in over 270 different minerals. The chief ore of aluminium
is bauxite.
Aluminium is remarkable for the metal's low density and its ability to
resist corrosion through the phenomenon of passivation. Aluminium and its alloys are vital to
the aerospace industry and important in transportation and structures, such as building facades and
window frames. The oxides and sulphates are the most useful compounds of aluminium.
Despite its prevalence in the environment, no known form of life uses
aluminium salts metabolically, but aluminium is well tolerated by plants and animals. Because of
their abundance, the potential for a biological role is of continuing interest and studies continue.
Characteristics:
Physical:
Aluminium is a relatively soft, durable, lightweight, ductile, and malleable metal with
appearance ranging from silvery to dull gray, depending on the surface roughness. It is
nonmagnetic and does not easily ignite. A fresh film of aluminium serves as a good reflector
(approximately 92%) of visible light and an excellent reflector (as much as 98%) of medium and
far infrared radiation. The yield strength of pure aluminium is 7–11 MPa, while aluminium
alloys have yield strengths ranging from 200 MPa to 600 MPa. Aluminium has about one-third
the density and stiffness of steel. It is easily machined, cast, drawn and extruded.

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Aluminium is a good thermal and electrical conductor, having 59% the conductivity of
copper, both thermal and electrical, while having only 30% of copper's density. Aluminium is
capable of superconductivity, with a superconducting critical temperature of 1.2 kelvin and a
critical magnetic field of about 100 gauss (10 milliteslas).
Chemical:
Corrosion resistance can be excellent because a thin surface layer
of aluminium oxide forms when the bare metal is exposed to air, effectively preventing
further oxidation, in a process termed passivation. The strongest aluminium alloys are less
corrosion resistant due to galvanic reactions with alloyed copper. This corrosion resistance is
greatly reduced by aqueous salts, particularly in the presence of dissimilar metals. In highly acidic
solutions, aluminium reacts with water to form hydrogen, and in highly alkaline ones to form aluminates
protective passivation under these conditions is negligible. Primarily because it is corroded by
dissolved chlorides, such as common sodium chloride, household plumbing is never made from
aluminium.
However, because of its general resistance to corrosion, aluminium is one of the few
metals that retains silvery reflectance in finely powdered form, making it an important component
of silver-collared paints. Aluminium mirror finish has the highest reflectance of any metal in the
200–400 nm (UV) and the 3,000–10,000 nm (far IR) regions; in the 400–700 nm visible range it
is slightly outperformed by tin and silver and in the 700–3000 nm (near IR) by silver, gold,
and copper.
Aluminium is oxidized by water at temperatures below 280 °C to produce hydrogen, aluminium
hydroxide and heat:
2 Al + 6 H2O → 2 Al(OH)3 + 3 H2

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Applications:
General use:
Aluminium is the most widely used non-ferrous metal. Global production of aluminium
in 2005 was 31.9 million tonnes. It exceeded that of any other metal except iron (837.5 million
tonnes). Forecast for 2012 was 42–45 million tonnes, driven by rising Chinese output. Aluminium
is almost always alloyed, which markedly improves its mechanical properties, especially
when tempered. For example, the common aluminium foils and beverage cans are alloys of 92%
to 99% aluminium. The main alloying agents are copper, zinc, magnesium, manganese,
and silicon (e.g., duralumin) with the levels of other metals in a few percent by weight.
Some of the many uses for aluminium metal are in:
 Transportation (automobiles, aircraft, trucks, railway cars, marine vessels, bicycles,
spacecraft, etc.) as sheet, tube, and castings.
 Packaging (cans, foil, frame of etc.).
 Food and beverage containers, because of its resistance to corrosion.
 Construction (windows, doors, siding, building wire, sheathing, roofing, etc.).
 A wide range of household items, from cooking utensils to baseball bats and watches.
 Street lighting poles, sailing ship masts, walking poles.
 Outer shells and cases for consumer electronics and photographic equipment.
 Electrical transmission lines for power distribution ( "creep" and oxidation are not issues in
this application as the terminations are usually multi-sided "crimps" which enclose all sides
of the conductor with a gas-tight seal).
 MKM steel and Alnico magnets.
 Super purity aluminium (SPA, 99.980% to 99.999% Al), used in electronics and CDs, and
also in wires/cabling.
 Heat sinks for transistors, CPUs, and other components in electronic appliances.
 Substrate material of metal-core copper clad laminates used in high brightness LED
lighting.

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 Light reflective surfaces and paint.
 Pyrotechnics, solid rocket fuels, and termite.
 Production of hydrogen gas by reaction with hydrochloric acid or sodium hydroxide.
 In alloy with magnesium to make aircraft bodies and other transportation components.
 Cooking utensils, because of its resistant to corrosion and light-weight.
 Coins in such countries as France, Italy, Poland, Finland, Romania, Israel, and the former
Yugoslavia struck from aluminium or an aluminium-copper alloy.
 Musical instruments. Some guitar models sport aluminium diamond plates on the surface
of the instruments, usually either chrome or black. Kramer Guitars and Travis Bean are
both known for having produced guitars with necks made of aluminium, which gives the
instrument a very distinctive sound. Aluminium is used to make some guitar resonators and
some electric guitar speakers.
1.1 Aluminium compounds
Because aluminium is abundant and most of its derivatives exhibit low toxicity, the
compounds of aluminium enjoy wide and sometimes large-scale applications.
Alumina
Aluminium oxide (Al2O3) and the associated oxy-hydroxides and tri hydroxides are
produced or extracted from minerals on a large scale. The great majority of this material is
converted to metallic aluminium. In 2013, about 10% of the domestic shipments in the United
States were used for other applications.[62] One major use is to absorb water where it is viewed as
a contaminant or impurity. Alumina is used to remove water from hydrocarbons in preparation for
subsequent processes that would be poisoned by moisture.
Aluminium oxides are common catalysts for industrial processes; e.g. the Claus
process to convert hydrogen sulphide to sulphur in refineries and to alkyl ate amines. Many
industrial catalysts are "supported" by alumina, meaning that the expensive catalyst material
(e.g., platinum) is dispersed over a surface of the inert alumina.
Being a very hard material (Mohs hardness 9), alumina is widely used as an abrasive; being
extraordinarily chemically inert, it is useful in highly reactive environments such as high lamps.

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Sulphates
Several sulphates of aluminium have industrial and commercial
application. Aluminium sulphate (Al2(SO4)3·(H2O)18) is produced on the annual scale of several
billions of kilograms. About half of the production is consumed in water treatment. The next
major application is in the manufacture of paper. It is also used as a mordant, in fire extinguishers,
in fireproofing, as a food additive (E number E173), and in leather tanning. Aluminium
ammonium sulphate, which is also called ammonium alum, (NH4)Al(SO4)2·12H2O, is used as a
mordant and in leather tanning,[63] as is aluminium potassium sulphate ([Al(K)](SO4)2)·(H2O)12.
The consumption of both alums is declining.
Chlorides
Aluminium chloride (AlCl3) is used in petroleum refining and in the production of
synthetic rubber and polymers. Although it has a similar name, aluminium chlorohydrate has
fewer and very different applications, particularly as a colloidal agent in water purification and
an antiperspirant. It is an intermediate in the production of aluminium metal.
Aluminium alloys in structural applications
Aluminium alloys with a wide range of properties are used in engineering structures.
Alloy systems are classified by a number system (ANSI) or by names indicating their main
alloying constituents (DIN and ISO).The strength and durability of aluminium alloys vary
widely, not only as a result of the components of the specific alloy, but also as a result of heat
treatments and manufacturing processes. A lack of knowledge of these aspects has from time to
time led to improperly designed structures and gained aluminium a bad reputation. One
important structural limitation of aluminium alloys is their fatigue strength. Unlike steels,
aluminium alloys have no well-defined fatigue limit, meaning that fatigue failure eventually
occurs, under even very small cyclic loadings. Engineers must assess applications and design
for a fixed and finite life of the structure, rather than infinite life.
Another important property of aluminium alloys is sensitivity to heat. Workshop
procedures are complicated by the fact that aluminium, unlike steel, melts without first glowing
red. Manual blow torch operations require additional skill and experience. Aluminium alloys,

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like all structural alloys, are subject to internal stresses after heat operations such as welding
and casting. The lower melting points of aluminium alloys make them more susceptible to
distortions from thermally induced stress relief. Stress can be relieved and controlled during
manufacturing by heat-treating the parts in an oven, followed by gradual cooling in
effect annealing the stresses.
The low melting point of aluminium alloys has not precluded use in rocketry, even
in combustion chambers where gases can reach 3500 K. The Agene upper stage engine used
regenerative cooled aluminium in some parts of the nozzle, including the thermally critical
throat region. Another alloy of some value is aluminium bronze (Cu-Al alloy).
1.2. ALUMINIUM A356 COMPOSITE MATERIAL
Composites are the combination of two or more constituent material with significantly
different physical and chemical properties with characteristics different from individual
components. They commonly consist of a continuous phase called matrix and discontinuous phase
in the form of fibres, whiskers, or particles called as reinforcement. Due to their characteristics of
behaviour with their high strength to weight ratio, Composite materials are gaining wide spread
acceptance.
A356 belongs to a group of hypo eutectic Al-Si alloys and has a wide field of
application in the automotive and avionics industries. It is used in the heat treated condition in
which a optimal ratio of physical and mechanical properties is obtained. The alloy solidifies in a
broad temperature interval (43 ºC) and is amenable to treatment in the semi solid state as well as
casting. For this reason it is the subject of rheological investigations, as well as methods of
treatment in the semi solid state. By these methods it is possible to obtain castings with reduced
porosity of a non dendrite structure and with good mechanical properties. Besides this the A356
alloy is used as a matrix for obtaining composites, which have an enhanced wear resistance,
favourable mechanical properties at room temperature and enhanced mechanical properties at
elevated temperatures. A356 solidifies in a wide enough temperature interval between the solidus
and liquid’s temperatures that it can be used as a matrix for obtaining composites by the compo
casting method. In this work for obtaining a composite unmodified A356 alloy was used so as to

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evaluate the effect of added particle strengtheners on the structure and mechanical properties of
the composite without modification effects. The results of preliminary mechanical tests on the
obtained composite were compared with the known values of mechanical properties of a
commercial modified heat treated A356 alloy
TABLE 1.2. CHEMICAL COMPOSITION OF A356
Element Si Cu Mg Mn Fe Zn Ni Ti Al
Wt(%) 7.2 0.02 0.29 0.01 0.18 0.01 0.02 0.11 Balance
Composition of al-356
Vibration:
Vibration is a mechanical phenomenon whereby oscillations occur about an
equilibrium point. The oscillations may be periodic such as the motion of a pendulum or
random such as the movement of a tire on a gravel road. Vibration is occasionally "desirable".
For example, the motion of a tuning fork, the reed in a woodwind instrument or harmonica, or
mobile or the cone of a loudspeaker is desirable vibration, necessary for the correct functioning
of the various devices. More often, vibration is undesirable, wasting energy and creating
unwanted sound–noise. For example the vibrational motions of engines, electric motors, or any
mechanical device in operation are typically unwanted. Such vibrations can be caused by
imbalances in the rotating parts, uneven friction, the meshing of gear teeth, etc. Careful designs
usually minimize unwanted vibrations. The study of sound and vibration are closely related.
Sound, or “pressure waves", are generated by vibrating structures
(e.g. vocal cords); these pressure waves can also induce the vibration of structures (e.g. ear
drum). Hence, when trying to reduce noise it is often a problem in trying to reduce vibration.
TYPES OF VIBRATION
Free vibration:
Free vibration occurs when a mechanical system is set off with an initial input and
then allowed to vibrate freely. Examples of this type of vibration are pulling child back on a

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swing and then letting go or hitting a tuning fork and letting it ring. The mechanical system
will then vibrate at one or more of its "natural frequency" and damp down to zero.
Forced vibration:
Forced vibration is when a time-varying disturbance (load, displacement or
velocity) is applied to a mechanical system. The disturbance can be a periodic, steady state
input, a transient input, or a random input. The periodic input can be a harmonic or a non-
harmonic disturbance. Examples of these types of vibration include a shaking washing machine
due to an imbalance, transportation vibration (caused by truck engine, springs, road, etc.), or
the vibration of a building during an earthquake. For linear systems, the frequency of the
steady-state vibration response resulting from the application of a periodic, harmonic input is
equal to the frequency of the applied force or motion, with the response magnitude being
dependent on the actual mechanical system.
Vibration testing:
Vibration testing is accomplished by introducing a forcing function into a structure,
usually with some type of shaker. Alternately, a DUT (device under test) is attached to the
"table" of a shaker. Vibration testing is performed to examine the response of a device under
test (DUT) to a defined vibration environment. The measured response may be fatigue life,
resonant frequencies or squeak and rattle sound output (NVH). Squeak and rattle testing is
Performed with a special type of quiet shaker that produces very low sound levels while under
operation.
1.3. 7075 ALUMINIUM ALLOY
Aluminium alloy 7075 is an aluminium alloy, with zinc as the primary alloying
element. It is strong, with strength comparable to many steels, and has good fatigue strength
and average machinability, but has less resistance to corrosion than many other Al alloys. Its
relatively high cost limits its use to applications where cheaper alloys are not suitable.7075
aluminium alloy's composition roughly includes 5.6–6.1% zinc, 2.1–2.5% magnesium, 1.2–
1.6% copper, and less than a half percent of silicon, iron, manganese, titanium, chromium, and
other metals. It is produced in many tempers, some of which are 7075-0, 7075-T6, 7075-T651.

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Basic properties
Mechanical properties
The mechanical properties of 7075 depend greatly on the temper of the material.
7075-0
Un-heat-treated 7075 (7075-0 temper) has maximum tensile strength no more than
280 MPa (40,000 psi), and maximum yield strength no more than 140 MPa (21,000 psi). The
material has an elongation (stretch before ultimate failure) of 9–10%. It is very highly
corrosion-resistant and has good strength
7075-T6
T6 temper 7075 has an ultimate tensile strength of 510–540 MPa (74,000–78,000 psi)
and yield strength of at least 430–480 MPa (63,000–69,000 psi). It has a failure elongation of
5–11%.The T6 temper is usually achieved by homogenizing the cast 7075 at 450 °C for several
hours, quenching, and then aging at 120 °C for 24 hours. This yields the peak strength of the
7075 alloy. The strength is derived mainly from finely dispersed eta and eta' precipitates both
within grains and along grain boundaries.
7075-T651
T651 temper 7075 has an ultimate tensile strength of 570 MPa (83,000 psi) and
yield strength of 500 MPa (73,000 psi). It has a failure elongation of 3–9%. These properties
can change depending on the form of material used. Thicker plate may exhibit lower strengths
and elongation than the numbers listed above.
7075-T7
T7 temper has an ultimate tensile strength of 505 MPa (73,200 psi) and a yield
strength of 435 MPa (63,100 psi). It has a failure elongation of 13%. T7 temper is achieved by
over re-aging (meaning aging past the peak hardness) the material. This is often accomplished
by aging at 100–120 °C for several hours and then at 160–180 °C for 24 hours or more. The T7
temper produces a micro-structure of mostly eta precipitates. In contrast to the T6 temper, these

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eta particles are much larger and prefer growth along the grain boundaries. This reduces the
susceptibility to stress corrosion cracking. T7 temper is equivalent to T73 temper.
7075-RRA
The retrogression and reage (RRA) temper is a multistage heat treatment temper.
Starting with a sheet in the T6 temper, it involves over aging past peak hardness (T6 temper) to
near the T7 temper. A subsequent reaging at 120 °C for 24 hours returns the hardness and
strength to or very nearly to T6 temper levels.
RRA treatments can be accomplished with many different procedures. The general guidelines
are retrogressing between 180–240 °C for 15 min 10 s.
Uses:
7000 series alloys such as 7075 are often used in transport applications, including
marine, automotive and aviation, due to their high strength-to-density ratio. Their strength and
light weight is also desirable in other fields. Rock climbing equipment, bicycle components,
inline skating-frames and hang glider airframes are commonly made from 7075 aluminium
alloy. Hobby grade RC models commonly use 7075 and 6061 for chassis plates. 7075 is used
in the manufacture of M16 rifles for the American military. In particular high quality M16 rifle
lower and upper receivers as well as extension tubes are typically made from 7075-T6
alloy. Desert Tactical Arms, SIG Sauer, and French armament company PGM use it for their
precision rifles. It is also commonly used in shafts for lacrosse sticks, such as the STX sabre,
and camping knife and fork sets. It is a common material used in competition yo-yos as well.
Due to its high strength, low density, thermal properties, and its ability to be highly polished,
7075 is widely used in mold tool manufacture. This alloy has been further refined into other
7000 series alloys for this application, namely 7050 and 7020.
History:
The first 7075 was developed in secret by a Japanese company, Sumitomo Metal, in
1943 7075 was eventually used for airframe production in the Imperial Japanese Navy. Trade
names7075 has been sold under various trade names including Zicral, Ergal, and Fortal
Constructal. Some 7000 series alloys sold under brand names for making molds include
Alumec 79, Alumec 89, Contal, Certal, Alumould, and Hokotol.

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CHAPTER-2
LITERATURE SURVEY
K. Radhakrishna [1] et al, he had used aluminium with copper and fly ash as
reinforcements and concluded that up to 15% the reinforcements are successfully dispersed in
the matrix and hardness, wear resistance increases upto 15 wt% addition of reinforcements.
Beinias [2] et al, used aluminium with fly ash as reinforcements and stated with
the addition of fly ash brittleness increases and corrosion increases as it form sporosity.
Sudarshan.
M.K. Surappa [3] et al, have synthesizedA356 Al–fly ash particle composites
.They studied mechanical properties and dry sliding wear and come into brief idea that The
damping capacity of composite increases with the increase in volume fraction of fly ash. The
6% of fly ash particles into A356 Al alloy show slow wear rates at low loads (10 and 20 N)
while 12% Offaly ash reinforced composites show lower wear rates compared to the
unreinforced alloy in the load range20–80 N. At higher load, subsurface delaminating and
thermal softening is the main mechanism in both the alloy as well in composites’.
C. Mishra [4] et al, and co workers has studied on Aluminium – fly ash
composite produced by impeller mixing and came into a brief idea that Up to 17wt% fly ash
reinforcement can be reinforced by liquid metallurgy route. The addition of magnesium into
the aluminium melt increase the wet ability and thus increase in the mechanical properties such
as hardness, tensile strength and the wear resistance is observed.
Ganesan Pandi [4] et al experimentally investigated the machining and tri
biological behaviour of hybrid aluminium composites. In this study, Silicon carbide
G Rajesh Babu et al [5] carried out the static and dynamic analysis of banjo
type rear axle housing by using FE method for two different materials like cast-iron and mild
steel. The induced deformation in cast-iron housing is greater than mild steel housing and also
the natural frequencies of the cast iron are lower than the mild steel. Also observed that the
stress induced in the cast iron is lower than the mild steel and concluded that the cast iron is
preferred for production of rear axle housing.

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Muhammad najib bin abdul hamid[6] conducted the experimental analysis on
drum brake and FEA analysis and concluded that improved material performs better.
Nam Ho Kim [7] et al conducted FE analysis and experimentation on
metal/metal wear in oscillatory contact and concluded that These results from the block on ring
experiments and the finite element simulation are close, supporting the possibility of using
finite element analysis coupled with specimen-level test data to estimate wear. A systematic
approach to numerical modelling, simulation, and validation for metal-on-metal wear is
developed using both experimental and computational tools. Maximum wear depth predictions
produced by finite element simulation of the block-on ring test agree to within 88% of the
experimental measurements without using curve fitting.

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CHAPTER-3
CREO
3.1. CAD
Computer aided design (cad) is defined as any activity that involves the effective
use of the computer to create, modify, analyze, or document an engineering design. CAD is
most commonly associated with the use of an interactive computer graphics system, referred to
as cad system. The term CAD/CAM system is also used if it supports manufacturing as well as
design applications.
3.2. Introduction to CREO
CREO is a suite of programs that are used in the design, analysis, and
manufacturing of a virtually unlimited range of product.
CREO is a parametric, feature-based solid modelling system, “Feature based”
means that you can create part and assembly by defining feature like pad, rib, slots, holes,
rounds, and so on, instead of specifying low-level geometry like lines, arcs, and circle&
features are specifying by setting values and attributes of element such as reference planes or
surfaces direction of creation, pattern parameters, shape, dimensions and others.
“Parametric” means that the physical shape of the part or assembly is driven by
the values assigned to the attributes (primarily dimensions) of its features. Parametric may
define or modify a feature’s dimensions or other attributes at any time.
For example, if your design intent is such that a hole is centered on a block, you
can relate the dimensional location of the hole to the block dimensions using a numerical
formula; if the block dimensions change, the centered hole position will be recomputed
automatically.

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“Solid Modeling” means that the computer model to create it able to contain all
the information that a real solid object would have. The most useful thing about the solid
modelling is that it is impossible to create a computer model that is ambiguous or physically
non-realizable.
There are six core CREO concepts. Those are:
 Solid Modelling
 Feature Based
 Parametric
 Parent / Child Relationships
 Associative
 Model Centric
3.3 Capabilities and Benefits:
1. Complete 3D modelling capabilities enable you to exceed quality arid time to arid time
to market goals.
2. Maximum production efficiency through automated generation of associative C tooling
design, assembly instructions, and machine code.
3. Ability to simulate and analysis virtual prototype to improve production performance
and optimized product design.
4. Ability to share digital product data seamlessly among all appropriate team members
5. Compatibility with myriad CAD tools-including associative data exchange and industry
standard data formats.
3.4 Features of CREO
CREO is a one-stop for any manufacturing industry. It offers effective feature,
incorporated for a wide variety of purpose. Some of the important features are as follows:

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 Simple and powerful tool
 Parametric design
 Feature-based approach
 Parent child relationship
 Associative and model centric
3.4.1. Simple and Powerful Tool
CREO tools are used friendly. Although the execution of any operation using the tool can
create a highly complex model.
3.4.2. Parametric Design
CREO designs are parametric. The term “parametric” means that the design
operations that are captured can be stored as they take place. They can be used effectively in
the future for modifying and editing the design. These types of modeling help in faster and
easier modifications of design.
3.4.3. Feature-Based Approach
Features are the basic building blocks required to create an object. CREO wildfire
models are based on the series of feature. Each feature builds upon the previous feature, to
create the model (only one single feature can be modified at a time). Each feature may appear
simple, individually, but collectively forms a complex part and assemblies.
The idea behind feature based modelling is that the designer construct on object,
composed of individual feature that describe the manner in which the geometry supports the
object, if its dimensions change. The first feature is called the base feature.
3.4.4. Parent Child Relationship
The parent child relationship is a powerful way to capture your design intent in a
model. This relationship naturally occurs among features, during the modelling process. When
you create a new feature, the existing feature that are referenced, become parent to the feature.

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3.4.5. Associative and Model Centric:
CREO drawings are model centric. This means that CREO models that are represented
in assembly or drawings are associative. If changes are made in one module, these will
automatically get updated in the referenced module.
3.5. CREO Basic Design Modes
When a design from conception to completion in CREO, the design information goes through
three basic design steps.
1. Creating the component parts of the design
2. Joining the parts in an assembly that records the relative position of the parts.
3. Creating mechanical drawing based on the information in the parts and the assembly.
3.6 Assembly in CREO:
Bottom-Up Design (Modeling):
The components (parts) are created first and then added to the assembly file. This
technique is particularly useful when parts already exist from previous designs and are being
re-used.
Top-Down Design (Modeling):
The assembly file is created first and then the components are created in the assembly
file. The parts are build relative to other components. Useful in new designs
In practice, the combination of Top-Down and Bottom-Up approaches is used. As you often
use existing parts and create new parts in order to meet your design needs.
Degrees of Freedom:
An object in space has six degrees of freedom.
• Translation – movement along X, Y, and Z axis (three degrees of freedom)
• Rotation – rotate about X, Y, and Z axis (three degrees of freedom)
Assembly Constraints:

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In order to completely define the position of one part relative to another, we must constrain all
of the degrees of freedom COINCIDENT, OFFSET
OFFSET
Two surfaces are made parallel with a specified offset distance.
.
COINCIDENT
Two selected surfaces become co-planar and face in the same direction. Can also be applied to revolved
surfaces. This constrains 3 degrees of freedom (two rotations and one translation). When Align is used
on revolved surfaces, they become coaxial (axes through the centres align).
CREO Modules:-
 Sketcher (2D)
 Part (3D)
 Assembly
 Drawing and Drafting
 Sheet Metal
 Surface modeling

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3D MODEL IS DEVELOPED USING CREO:-
Open pro-e/creo
New enter nameal356 modelok

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Then we will get a new window
Create model with dimensions

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Create sketch with values
The above sketch is our final sketch
Now select extrudeselect sketchok100mmok
Aluminium bar.
Circular bar diameter

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Circular bar extrusion length
INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who
utilized the Ritz method of numerical analysis and minimization of variational calculus to obtain
approximate solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J.
Turner, R. W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical
analysis. The paper centered on the "stiffness and deflection of complex structures".
FEA consists of a computer model of a material or design that is stressed and analyzed for specific
results. It is used in new product design, and existing product refinement. A company is able to
verify a proposed design will be able to perform to the client's specifications prior to
manufacturing or construction. Modifying an existing product or structure is utilized to qualify the
product or structure for a new service condition. In case of structural failure, FEA may be used to
help determine the design modifications to meet the new condition.
There are generally two types of analysis that are used in industry: 2-D modelling, and
3-D modelling. While 2-D modelling conserves simplicity and allows the analysis to be run on a
relatively normal computer, it tends to yield less accurate results. 3-D modelling, however,
produces more accurate results while sacrificing the ability to run on all but the fastest computers
effectively. Within each of these modelling schemes, the programmer can insert numerous

23. 23
algorithms (functions) which may make the system behave linearly or non-linearly. Linear
systems are far less complex and generally do not take into account plastic deformation. Non-
linear systems do account for plastic deformation, and many also are capable of testing a material
all the way to fracture.
FEA uses a complex system of points called nodes which make a grid called a mesh.
This mesh is programmed to contain the material and structural properties which define how the
structure will react to certain loading conditions. Nodes are assigned at a certain density
throughout the material depending on the anticipated stress levels of a particular area. Regions
which will receive large amounts of stress usually have a higher node density than those which
experience little or no stress. Points of interest may consist of: fracture point of previously tested
material, fillets, corners, complex detail, and high stress areas. The mesh acts like a spider web in
that from each node, there extends a mesh element to each of the adjacent nodes. This web of
vectors is what carries the material properties to the object, creating many elements.
A wide range of objective functions (variables within the system) are available for
minimization or maximization:
 Mass, volume, temperature
 Strain energy, stress strain
 Force, displacement, velocity, acceleration
 Synthetic (User defined)
There are multiple loading conditions which may be applied to a system. Some examples are
shown:
 Point, pressure, thermal, gravity, and centrifugal static loads
 Thermal loads from solution of heat transfer analysis
 Enforced displacements
 Heat flux and convection
 Point, pressure and gravity dynamic loads

24. 24
Each FEA program may come with an element library, or one is constructed over time. Some
sample elements are:
 Rod elements
 Beam elements
 Plate/Shell/Composite elements
 Shear panel
 Solid elements
 Spring elements
 Mass elements
 Rigid elements
 Viscous damping elements
Many FEA programs also are equipped with the capability to use multiple materials within the
structure such as:
 Isotropic, identical throughout
 Orthotropic, identical at 90 degrees
 General anisotropic, different throughout
4.1 TYPES OF ENGINEERING ANALYSIS
Structural analysis consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Non-linear models consist
of stressing the material past its elastic capabilities. The stresses in the material then vary with
the amount of deformation as in.
Vibrational analysis is used to test a material against random vibrations, shock, and impact.
Each of these incidences may act on the natural vibration frequency of the material which, in
turn, may cause resonance and subsequent failure.

25. 25
Fatigue analysis helps designers to predict the life of a material or structure by showing the
effects of cyclic loading on the specimen. Such analysis can show the areas where crack
propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance
of the material.
Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or
structure. This may consist of a steady-state or transient transfer. Steady-state transfer refers to
constant thermo properties in the material that yield linear heat diffusion.
4. 2Results of Finite Element Analysis
FEA has become a solution to the task of predicting failure due to unknown stresses by
showing problem areas in a material and allowing designers to see all of the theoretical stresses
within. This method of product design and testing is far superior to the manufacturing costs
which would accrue if each sample was actually built and tested.
In practice, a finite element analysis usually consists of three principal steps:
1. Pre processing: The user constructs a model of the part to be analyzed in which the
geometry is divided into a number of discrete sub regions, or elements," connected at
discrete points called nodes." Certain of these nodes will have fixed displacements, and
others will have prescribed loads. These models can be extremely time consuming to
prepare, and commercial codes vie with one another to have the most user-friendly
graphical “pre processor" to assist in this rather tedious chore. Some of these pre
processors can overlay a mesh on a pre existing CAD file, so that finite element
analysis can be done conveniently as part of the computerized drafting-and-design
process.
2. Analysis: The dataset prepared by the pre processor is used as input to the finite
element code itself, which constructs and solves a system of linear or nonlinear
algebraic equations
Kijuj = fi
Where u and f are the displacements and externally applied forces at the nodal points.
The formation of the K matrix is dependent on the type of problem being attacked, and this
module will outline the approach for truss and linear elastic stress analyses. Commercial codes
may have very large element libraries, with elements appropriate to a wide range of problem

26. 26
types. One of FEA's principal advantages is that many problem types can be addressed with the
same code, merely by specifying the appropriate element types from the library.
3. Postprocessing: In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot spots this
way, and modern codes use graphical displays to assist in visualizing the results. A
typical postprocessor display overlays coloured contours representing stress levels on
the model, showing a full field picture similar to that of photo elastic or moiré
experimental results
CHAPTER-5
INTRODUCTION TO ANSYS
5.1. ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package. Finite
Element Analysis is a numerical method of deconstructing a complex system into very small
pieces (of user-designated size) called elements. The software implements equations that
govern the behaviour of these elements and solves them all; creating a comprehensive
explanation of how the system acts as a whole. These results then can be presented in
tabulated, or graphical forms. This type of analysis is typically used for the design and
optimization of a system far too complex to analyze by hand. Systems that may fit into this
category are too complex due to their geometry, scale, or governing equations.
ANSYS is the standard FEA teaching tool within the Mechanical Engineering
Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well
as the Physics and Chemistry departments.
ANSYS provides a cost-effective way to explore the performance of products or
processes in a virtual environment. This type of product development is termed virtual
prototyping.With virtual prototyping techniques, users can iterate various scenarios to optimize
the product long before the manufacturing is started. This enables a reduction in the level of

27. 27
risk, and in the cost of ineffective designs. The multifaceted nature of ANSYS also provides a
means to ensure that users are able to see the effect of a design on the whole behavior of the
product, be it electromagnetic, thermal, mechanical etc
5.1.1 GENERIC STEPS TO SOLVING ANY PROBLEM IN ANSYS:
Like solving any problem analytically, you need to define (1) your solution domain,
(2) the physical model, (3) boundary conditions and (4) the physical properties. You then solve
the problem and present the results. In numerical methods, the main difference is an extra step
called mesh generation. This is the step that divides the complex model into small elements
that become solvable in an otherwise too complex situation. Below describes the processes in
terminology slightly more attune to the software
5.1.1.1 BUILD GEOMETRY
Construct a two or three dimensional representation of the object to be modelled and
tested using the work plane coordinates system within ANSYS.
5.1.1.2 MATERIAL PROPERTIES
Now that the part exists, define a library of the necessary materials that compose the
object (or project) being modelled. This includes thermal and mechanical properties.
5.1.1.3 GENERATE MESH
At this point ANSYS understands the makeup of the part. Now define how the
modeled system should be broken down into finite pieces.
5.1.1.4 APPLY LOADS
Once the system is fully designed, the last task is to burden the system with constraints,
such as physical loadings or boundary conditions.
5.1.1.5 OBTAIN SOLUTION
This is actually a step, because ANSYS needs to understand within what state (steady
state, transient… etc.) the problem must be solved.
5.1.1.6 PRESENT THE RESULTS
After the solution has been obtained, there are many ways to present ANSYS’ results,
choose from many options such as tables, graphs, and contour plots.
5.2 SPECIFIC CAPABILITIES OF ANSYS:
5.2.1 STRUCTURAL

28. 28
Structural analysis is probably the most common application of the finite element
method as it implies bridges and buildings, naval, aeronautical, and mechanical structures such
as ship hulls, aircraft bodies, and machine housings, as well as mechanical components such as
pistons, machine parts, and tools.
· Static Analysis - Used to determine displacements, stresses, etc. under static loading
conditions. ANSYS can compute both linear and nonlinear static analyses. Nonlinearities can
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity, contact
surfaces, and creep.
Modal Analysis
A modal analysis is typically used to determine the vibration characteristics (natural
frequencies and mode shapes) of a structure or a machine component while it is being
designed. It can also serve as a starting point for another, more detailed, dynamic analysis, such
as a harmonic response or full transient dynamic analysis.
Modal analyses, while being one of the most basic dynamic analysis types available in
ANSYS, can also be more computationally time consuming than a typical static analysis. A
reduced solver, utilizing automatically or manually selected master degrees of freedom is used
to drastically reduce the problem size and solution time.
Harmonic Analysis - Used extensively by companies who produce rotating machinery,
ANSYS Harmonic analysis is used to predict the sustained dynamic behavior of structures to
consistent cyclic loading. Examples of rotating machines which produced or are subjected to
harmonic loading are:
 Turbines
o Gas Turbines for Aircraft and Power Generation
o Steam Turbines
o Wind Turbine
o Water Turbines
o Turbo pumps
 Internal Combustion engines

29. 29
 Electric motors and generators
 Gas and fluid pumps
 Disc drives
A harmonic analysis can be used to verify whether or not a machine design will successfully
overcome resonance, fatigue, and other harmful effects of forced vibrations.
· Transient Dynamic Analysis - Used to determine the response of a structure to
arbitrarily time-varying loads. All nonlinearities mentioned under Static Analysis above are
allowed.
· Buckling Analysis - Used to calculate the buckling loads and determine the buckling
mode shape. Both linear (eigen value) buckling and nonlinear buckling analyses are possible.
In addition to the above analysis types, several special-purpose features are
available such as Fracture mechanics, Composite material analysis, Fatigue, and both p-
Method and Beam analyses.
5.2.2 THERMAL
ANSYS is capable of both steady state and transient analysis of any solid with
thermal boundary conditions. Steady-state thermal analyses calculate the effects of steady
thermal loads on a system or component. Users often perform a steady-state analysis before
doing a transient thermal analysis, to help establish initial conditions. A steady-state analysis
also can be the last step of a transient thermal analysis; performed after all transient effects
have diminished. ANSYS can be used to determine temperatures, thermal gradients, heat flow
rates, and heat fluxes in an object that are caused by thermal loads that do not vary over time.
Such loads include the following:
· Convection
· Radiation
· Heat flow rates
· Heat fluxes (heat flow per unit area)
· Heat generation rates (heat flow per unit volume)
· Constant temperature boundaries

30. 30
A steady-state thermal analysis may be either linear, with constant material
properties; or nonlinear, with material properties that depend on temperature. The thermal
properties of most material vary with temperature. This temperature dependency being
appreciable, the analysis becomes nonlinear. Radiation boundary conditions also make the
analysis nonlinear. Transient calculations are time dependent and ANSYS can both solve
distributions as well as create video for time incremental displays of models.
5.2.3 FLUID FLOW
The ANSYS/FLOTRAN CFD (Computational Fluid Dynamics) offers
comprehensive tools for analyzing two-dimensional and three-dimensional fluid flow fields.
ANSYS is capable of modeling a vast range of analysis types such as: airfoils for pressure
analysis of airplane wings (lift and drag), flow in supersonic nozzles, and complex, three-
dimensional flow patterns in a pipe bend. In addition, ANSYS/FLOTRAN could be used to
perform tasks including:
· Calculating the gas pressure and temperature distributions in an engine exhaust manifold
· Studying the thermal stratification and breakup in piping systems
· Using flow mixing studies to evaluate potential for thermal shock
· Doing natural convection analyses to evaluate the thermal performance of chips in
electronic enclosures
· Conducting heat exchanger studies involving different fluids separated by solid regions
5.2.4 ACOUSTICS / VIBRATION
ANSYS is capable of modelling and analyzing vibrating systems in order to that
vibrate in order to analyze. Acoustics is the study of the generation, propagation, absorption,
and reflection of pressure waves in a fluid medium. Applications for acoustics include the
following:
· Sonar - the acoustic counterpart of radar
· Design of concert halls, where an even distribution of sound pressure is desired
· Noise minimization in machine shops
· Noise cancellation in automobiles
· Underwater acoustics

31. 31
· Design of speakers, speaker housings, acoustic filters, mufflers, and many other similar
devices.
· Geophysical exploration Within ANSYS, an acoustic analysis usually involves
modelling a fluid medium and the surrounding structure. Characteristics in question include
pressure distribution in the fluid at different frequencies, pressure gradient, and particle
velocity, the sound pressure level, as well as, scattering, diffraction, transmission, radiation,
attenuation, and dispersion of acoustic waves. A coupled acoustic analysis takes the fluid
structure interaction into account. An uncoupled acoustic analysis models only the fluid and
ignores any fluid-structure interaction.
The ANSYS program assumes that the fluid is compressible, but allows only relatively
small pressure changes with respect to the mean pressure. Also, the fluid is assumed to be non-
flowing and in viscid (that is, viscosity causes no dissipative effects). Uniform mean density
and mean pressure are assumed, with the pressure solution being the deviation from the mean
pressure, not the absolute pressure.
5.2.5 COUPLED FIELDS
A coupled-field analysis is an analysis that takes into account the interaction
(coupling) between two or more disciplines (fields) of engineering. A piezoelectric analysis,
for example, handles the interaction between the structural and electric fields: it solves for the
voltage distribution due to applied displacements, or vice versa. Other examples of coupled-
field analysis are thermal-stress analysis, thermal-electric analysis, and fluid-structure analysis.
Some of the applications in which coupled-field analysis may be required are pressure vessels
(thermal-stress analysis), fluid flow constrictions (fluid-structure analysis), induction heating
(magnetic-thermal analysis), ultrasonic transducers (piezoelectric analysis), magnetic forming
(magneto-structural analysis), and micro-electro mechanical systems (MEMS).

32. 32
6. ANSYS PROCESS
IMPORTINGTHE COMPONEENT FROM CAD (CREO) TOOL TO CAE TOOL (ANSYS):
STRUCTURAL ANALYSIS:-
1. Click on Ansys workbench
Static structural
Engineering dataright click enter values
FOR
Structural steel
Ex: - 200*10^9 Pa
Poison ratio: 0.30
Density: 7850 Kg/m^3
Yield strength: 250 Mpa

33. 33
Steel bar Weight
AL-356
Ex: 72.4*10^9 Pa
Poison ratio: 0.33
Density: 2670 kg/m^3
Yield strength: 165 Mpa
Al-7075
Ex: 71.7*10^9 Pa
Poison ratio: 0.33
Density: 2810 kg/m^3
Yield strength: 480 Mpa

34. 34
4. Geometry right click import geometry import iges format model
Model imported from pro-e tool in IGES format.
After importing model just click on geometry option then we will get selection of material.
From engineering data here we already applied steel and al-7075 material and al-356properties.
Now select one material after one.
Imported Model View In Ansys.

35. 35
Meshing: - Volume Mesh - Tetmesh.
After completion of material selection here we have to create meshing for each object meshing
means it is converting single part into no of parts. And this mesh will transfer applied loads for
overall object. After completion meshing only we can solve our object. Without mesh we cannot
solve our problem. And here we are using tetra meshing and the model shown in below.
Tet Volume Mesh

36. 36
After completion of meshing now we have to apply boundary conditions according to our
requirement. Fix both sides of square bar and apply pressure on top surface 2Mpa.
Boundary conditions

37. 37
Select geometry assign material properties
Click on static structural  supports fixed support supportsselect edges
 Loadspressure 2*10^6 pa apply
. Solutiondeformationsolve
Repeat same process for von-misess stress, factor of safety then solve

38. 38
Results:
Material: STEEL
Deformation:
The above figure shows the results of square bar with steel material deformation for
above applied boundary conditions. And here we have maximum deformation value is
0.034379mm which is shown in red colour and minimum value is 0mm which is shown in blue
colour
The above figure shows the results of circular bar with steel material deformation for
above applied boundary conditions. And here we have maximum deformation value is

39. 39
0.057048mm which is shown in red colour and minimum value is 0mm which is shown in blue
colour
Stress
The above figure shows the results of square bar with steel materials stress values for
above applied boundary conditions. And here we have maximum stress value is 86.549Mpa which
is shown in red colour and minimum value is 0.89026Mpa which is shown in blue colour.
The above figure shows the results of circular bar with steel materials stress values for
above applied boundary conditions. And here we have maximum stress value is 165.7Mpa which
is shown in red colour and minimum value is 0.92251Mpa which is shown in blue colour.

40. 40
Safety factor
The above figure shows the results of square bar with steel materials safety factor
values for above applied boundary conditions. And here we have 2.885 safety factor it is very
high safety factor value that means it has very good strength
The above figure shows the results of circular bar with steel materials safety factor
values for above applied boundary conditions. And here we have 1.5087 safety factors it is very
high safety factor value that means it has very good strength

41. 41
Results for
Material: Al-356
Deformation
The above figure shows the results of square bar with Al-356 material deformation for
above applied boundary conditions. And here we have maximum deformation value is
0.09473mm which is shown in red colour and minimum value is 0mm which is shown in blue
colour

42. 42
The above figure shows the results of circular bar with Al-356 material deformation for
above applied boundary conditions. And here we have maximum deformation value is
0.15729mm which is shown in red colour and minimum value is 0mm which is shown in blue
colour
Stress
The above figure shows the results of square bar with Al-356 material stress values for
above applied boundary conditions. And here we have maximum stress value is 85.213Mpa which
is shown in red colour and minimum value is 0.88376Mpa which is shown in blue colour

43. 43
The above figure shows the results of circular bar with Al-356 material stress values for
above applied boundary conditions. And here we have maximum stress value is 163.18Mpa which
is shown in red colour and minimum value is 0.91159Mpa which is shown in blue colour
Safety factor
The above figure shows the results of square bar with al-356 materials safety factor
values for above applied boundary conditions. And here we have 1.9363 safety factors it is very
high safety factor value that means it has very good strength

44. 44
The above figure shows the results of circular bar with al-356 materials safety factor
values for above applied boundary conditions. And here we have 1.0111 safety factors it is going
to break if we apply any external force more than applied boundary condition.
Results for
Material: Al-7075
Deformation
The above figure shows the results of square bar with Al-7075 material deformation for above
applied boundary conditions. And here we have maximum deformation value is 0.095655mm
which is shown in red colour and minimum value is 0mm which is shown in blue colour

45. 45
The above figure shows the results of circular bar with Al-7075 material deformation for above
applied boundary conditions. And here we have maximum deformation value is 0.14789mm
which is shown in red colour and minimum value is 0mm which is shown in blue colour
Stress
The above figure shows the results of square bar with Al-7075 material stress values for
above applied boundary conditions. And here we have maximum stress value is 85.213Mpa which
is shown in red colour and minimum value is 0.88376Mpa which is shown in blue colour

46. 46
The above figure shows the results of circular bar with Al-7075material stress values
for above applied boundary conditions. And here we have maximum stress value is 163.18Mpa
which is shown in red colour and minimum value is 0.91159Mpa which is shown in blue colour
Safety factor
The above figure shows the results of square bar with al-356 materials safety factor
values for above applied boundary conditions. And here we have 5.9029 safety factors it is very
high safety factor value that means it has very good strength

47. 47
The above figure shows the results of circular bar with al-7075 materials safety factor
values for above applied boundary conditions. And here we have 3.0824 safety factors it is very
high safety factor value that means it has very good strength
Tables:
Square bar table:
Material Deformation(mm) safety factor stress(Mpa)
Steel 0.034379 2.8885 86.549
Al-356 0.09473 1.9363 85.213
Al-7075 0.095655 5.9029 85.213
Table 4: Results for All Materials
Circular bar table:
Material Deformation(mm) safety factor stress(Mpa)
Steel 0.057048 1.5087 165.7
Al-356 0.15729 1.0111 163.18
Al-7075 0.14789 3.0824 163.18

48. 48
From the above table we can say that for all 3 materials the stress values are nearby
same and al-356 & al-7075 and also circular bar has got the same stress for 3 materials but the
safety factor values are high for al-7075 so that among all these 3 materials al-7075 have
greater strength compare to other 2materials.from the results circular bar has 2times more
stress values compare with square bar.
GRAPHS
SQUARE BAR
Deformation:
0
0.02
0.04
0.06
0.08
0.1
0.12
Steel Al-356 Al-7075
Deformation(mm)
Deformation(mm)

49. 49
Safety factor
Stress:
0
1
2
3
4
5
6
7
Steel Al-356 Al-7075
safety factor
safety factor
84
84.5
85
85.5
86
86.5
87
Steel Al-356 Al-7075
stress(Mpa)
stress(Mpa)

50. 50
GRAPHS
CIRCULAR BAR
Deformation:
Safety factor
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
Steel Al-356 Al-7075
Deformation(mm)
Deformation(mm)

51. 51
Stress:
0
0.5
1
1.5
2
2.5
3
3.5
Steel Al-356 Al-7075
safety factor
safety factor
161.5
162
162.5
163
163.5
164
164.5
165
165.5
166
Steel Al-356 Al-7075
stress(Mpa)
stress(Mpa)

52. 52
Modal analysis (Dynamic Analysis)
Import geometryAssign material properties
Static structuralfixed supportselect edges
Analysis settingsno of modes5
Solution deformation
Results:
Steel
Mode1

53. 53
The above figure shows that square steel bar natural frequency results and it has 4931.hz for
Mode1
The above figure shows that circular steel bar natural frequency results and it has 4326.6.hz for
mode1
Compare with both bars square bar has more natural frequency it means it has good strength
compare with circular bar.
Mode2
The above figure shows that square steel bar natural frequency results and it has 4931.hz for
mode2

54. 54
The above figure shows that circular steel bar natural frequency results and it has 4329.5.hz for
mode2
Mode3
The above figure shows that square steel bar natural frequency results and it has 12654.hz for
mode3

55. 55
The above figure shows that circular steel bar natural frequency results and it has 11290.hz for
mode3
Mode4
The above figure shows that square steel bar natural frequency results and it has 12654.hz for
mode4

56. 56
The above figure shows that circular steel bar natural frequency results and it has 11298.hz for
mode4
Mode5
The above figure shows that square steel bar natural frequency results and it has 14501.hz for
mode5

57. 57
The above figure shows that square steel bar natural frequency results and it has 15651.hz for
mode5
Results
Al-356
Mode1
The above figure shows that square AL-356 bar natural frequency results and it has 5094.9.hz
for mode1

58. 58
The above figure shows that circular al-356 bar natural frequency results and it has 4469.2.hz
for mode1
Mode2
The above figure shows that square al-356 bar natural frequency results and it has 5094.9.hz
for mode2

59. 59
The above figure shows that circular al-356 bar natural frequency results and it has 4472.7.hz
for mode2
Mode3
The above figure shows that square al-356 bar natural frequency results and it has 13056 hz for
mode3

60. 60
The above figure shows that circular al-356 bar natural frequency results and it has 11651.hz
for mode3
Mode4
The above figure shows that square al-356 bar natural frequency results and it has 13056.hz for
mode4

61. 61
The above figure shows that circular al-356 bar natural frequency results and it has 11660.hz
for mode4
Mode5
The above figure shows that square al-356 bar natural frequency results and it has 14792.hz
for mode5

62. 62
The above figure shows that circular al-356 bar natural frequency results and it has 15963.hz
for mode5
Results
Al-7075
Mode1
The above figure shows that square al-7075 bar natural frequency results and it has 5121.7.hz
for mode1

63. 63
The above figure shows that circular steel bar natural frequency results and it has 4326.6.hz for
mode1
Mode2
The above figure shows that square al-7075 bar natural frequency results and it has 5121.7.hz
for mode2

64. 64
The above figure shows that circular al-7075 bar natural frequency results and it has 4329.5.hz
for mode2
Mode3
The above figure shows that square al-7075 bar natural frequency results and it has 13125.hz
for mode3

65. 65
The above figure shows that circular bar natural frequency results and it has 11290.hz for
mode3
Mode4
The above figure shows that square al-7075 bar natural frequency results and it has 13125.hz
for mode4

66. 66
The above figure shows that circular al-7075 bar natural frequency results and it has 11298.hz
for mode4
Mode5
The above figure shows that square al-7075 bar natural frequency results and it has 14870.hz
for mode5

67. 67
The above figure shows that circular al-7075 bar natural frequency results and it has 15651.hz
for mode5
Tables:
Square bar
No of mode Steel frequency (Hz) Al-356(Hz) Al-7075(Hz)
Mode1 4931 5094.9 4942.3
Mode2 4931 5094.9 4942.3
Mode3 12654 13056 12665
Mode4 12654 13056 12665
Mode5 14501 14792 14349
Table 5: frequency’s for all materials
The above table shows different frequencies for all 3 materials and these frequencies indicates
as natural frequency’s compare to al-356 material al-7075 has less frequencies values here
Circular bar
No of mode Steel frequency (Hz) Al-356(Hz) Al-7075(Hz)
Mode1 4326.6 4469.2 4492.7
Mode2 4329.5 4472.7 4496.2
Mode3 11290 11651 11713
Mode4 11298 11660 11722
Mode5 15651 15963 16047

68. 68
Graphs
Square bar natural frequency’s:
Circular bar natural frequency’s
0
2000
4000
6000
8000
10000
12000
14000
16000
Axis
Title
Chart Title
Steel frequency
(Hz)
Al-356(Hz)
Al-7075(Hz)
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Mode1Mode2Mode3Mode4Mode5
Axis
Title
natural frequencys
Steel frequency
(Hz)
Al-356(Hz)
Al-7075(Hz)

69. 69
CHAPTER-6
CONCLUSION
In this project we analyses on al-alloy square and circular bars with 2Mpa pressure.
And then observing results with variant materials like steel and al-a356 and al-7075 alloys.
From all these results we can say al-7075 has been produced less stress (85.213Mpa) compare
to other metals. If we observe here al-356 also produces same stress (85.213Mpa) like al-7075,
but when we comparing strain energy and safety factor al-7075 so far better than al-356.
Material Deformation(mm) strain energy(mJ) safety factor stress(Mpa)
Steel 0.034379 0.78903 2.8885 86.549
Al-356 0.09473 2.1483 1.9363 85.213
Al-7075 0.095655 2.1692 5.9029 85.213
After this study we conclude that the damping properties of square bar aluminium7075
are much better than the remaining metals, a hi grade damping can be obtained by al-7075.
The frequencies recorded during analysis are listed above in the table it clearly shows
that aluminium7075 recorded less frequencies than al-356, because al-356 is much stiffer then
aluminium-7075 But if the frequencies match with the natural frequencies the structure then
the structure will fail so we should provide damping, and also the frequencies increase with
increase in mode so we should reduce the modes by providing rigid supports and dampers. If
damping is not possible then we should increase the natural frequency by redesigning the
structure.
From all these results we can say al-7075 is having good strength to weight ratio when
compare to other materials.

70. 70
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