- Gear tooth stress analysis was optimized by introducing a stress relief hole. Finite element analysis and experimental photoelastic testing validated a 15% reduction in maximum stress with only a 2.3% increase in deflection.
- Missile design optimization balances multiple design variables across disciplines like aerodynamics, propulsion, and structure to improve performance while reducing mass. Optimization algorithms consider constraints to find an optimal configuration.
- Machine design optimization more broadly works to improve performance, reduce stresses, lower costs, and facilitate mass production for various mechanical components and systems.
Francesco Boscolo, member of Tecnalia Offshore Energy Area, presents at FOWT 2018 conference in Marseille a methodology for the design of an umbilical cable for floating offshore platforms, based on static and dynamic analysis in a time domain approach, in order to get a significative time-consuming reduction in the design stage.
ANALYSIS OF STRESS RELIEVING FEATURES OF ASYMMETRIC SPUR GEARijiert bestjournal
This document analyzes stress relieving features of asymmetric spur gears through finite element analysis and experimental testing. It begins with an introduction to gear technology, gear classifications, and the importance of asymmetric gears. It then describes the objectives of analyzing stress relieving circular holes. The methodology includes modeling gears in CATIA and analyzing stresses in ANSYS. Results show adding circular holes, particularly at the tooth center, reduces maximum principal stress compared to simple spur gears. Experimental strain gauge tests validate the FEA results. The study concludes circular stress relieving features are effective at redistributing stress and improving gear strength and durability.
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
John deere cleaning fan_assemblymodule_hfyifenchang
The document analyzes the assembly of a cleaning fan module to identify human factors issues. It finds the current design requires unnatural postures that increase injury risk. A proposed redesign with an adjustable platform and retractable step is modeled. Both qualitative and quantitative analyses show the proposed design reduces spinal loads, discomfort, and fatigue while allowing more natural postures. Future work includes further virtual testing and real-world experiments with workers.
The document summarizes a presentation on modeling rubber bushings using fractional derivatives. It describes a fractional Kelvin-Voigt bushing model that captures frequency-dependent stiffness and damping with few parameters. Test data from a class-8 truck bushing showed the model matched experimental dynamic stiffness and damping over 1-50Hz, performing better than a standard 2-parameter model. The model was then implemented in a full vehicle model in ADAMS.
This document provides an overview of machine design and summarizes key areas of research. It discusses machine design topics like stress analysis, failure theories, and machine elements. Research applications mentioned include finite element analysis of gear teeth to reduce stress and optimize design, and designing a customized knee implant using stress analysis and manufacturing techniques. The document then focuses on analyzing stresses in gear teeth using FEA and experimental methods like photoelasticity to validate models. It describes optimizing a gear tooth design by introducing a stress relief hole to minimize root stress.
A Review Paper on Design and Analysis of Helical Gear Using ANSYS, FEM & AGMA...IRJET Journal
This document reviews research on analyzing the strength of helical gear teeth. It summarizes 6 research papers that used theoretical, analytical and finite element methods to calculate bending and contact stresses on helical gear teeth. The studies found that finite element analysis results aligned closely with theoretical values. Key factors analyzed included varying helix angle, face width, pressure angle and material. Increased helix angle and decreased face width were found to increase contact stress. Finite element analysis was found to provide a more accurate model than theoretical equations by considering a continuous load rather than a single point load.
Francesco Boscolo, member of Tecnalia Offshore Energy Area, presents at FOWT 2018 conference in Marseille a methodology for the design of an umbilical cable for floating offshore platforms, based on static and dynamic analysis in a time domain approach, in order to get a significative time-consuming reduction in the design stage.
ANALYSIS OF STRESS RELIEVING FEATURES OF ASYMMETRIC SPUR GEARijiert bestjournal
This document analyzes stress relieving features of asymmetric spur gears through finite element analysis and experimental testing. It begins with an introduction to gear technology, gear classifications, and the importance of asymmetric gears. It then describes the objectives of analyzing stress relieving circular holes. The methodology includes modeling gears in CATIA and analyzing stresses in ANSYS. Results show adding circular holes, particularly at the tooth center, reduces maximum principal stress compared to simple spur gears. Experimental strain gauge tests validate the FEA results. The study concludes circular stress relieving features are effective at redistributing stress and improving gear strength and durability.
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
John deere cleaning fan_assemblymodule_hfyifenchang
The document analyzes the assembly of a cleaning fan module to identify human factors issues. It finds the current design requires unnatural postures that increase injury risk. A proposed redesign with an adjustable platform and retractable step is modeled. Both qualitative and quantitative analyses show the proposed design reduces spinal loads, discomfort, and fatigue while allowing more natural postures. Future work includes further virtual testing and real-world experiments with workers.
The document summarizes a presentation on modeling rubber bushings using fractional derivatives. It describes a fractional Kelvin-Voigt bushing model that captures frequency-dependent stiffness and damping with few parameters. Test data from a class-8 truck bushing showed the model matched experimental dynamic stiffness and damping over 1-50Hz, performing better than a standard 2-parameter model. The model was then implemented in a full vehicle model in ADAMS.
This document provides an overview of machine design and summarizes key areas of research. It discusses machine design topics like stress analysis, failure theories, and machine elements. Research applications mentioned include finite element analysis of gear teeth to reduce stress and optimize design, and designing a customized knee implant using stress analysis and manufacturing techniques. The document then focuses on analyzing stresses in gear teeth using FEA and experimental methods like photoelasticity to validate models. It describes optimizing a gear tooth design by introducing a stress relief hole to minimize root stress.
A Review Paper on Design and Analysis of Helical Gear Using ANSYS, FEM & AGMA...IRJET Journal
This document reviews research on analyzing the strength of helical gear teeth. It summarizes 6 research papers that used theoretical, analytical and finite element methods to calculate bending and contact stresses on helical gear teeth. The studies found that finite element analysis results aligned closely with theoretical values. Key factors analyzed included varying helix angle, face width, pressure angle and material. Increased helix angle and decreased face width were found to increase contact stress. Finite element analysis was found to provide a more accurate model than theoretical equations by considering a continuous load rather than a single point load.
Objective function to Optimize Bending Stress at Critical Section of Asymmetr...IOSR Journals
Main objective of this paper is to optimize Bending stress at critical section, which is most important
parameter in gear design. It must be low as low possible. Bending Stress optimize by all affected Parameters of
asymmetric spur gear tooth at critical section of tooth. Objective function for bending stress at critical section
has been developed to minimize/optimize bending stress at critical section thickness of asymmetric spur gear
tooth. A programme has been developed in SciLab software with help of developed objective function to
optimize the bending stress at critical section of an asymmetric spur gear. Result obtains from SciLab
programme compared to ANSYS software and give comment on validation of developed objective function
The machine design may be classified as follows :
Adaptive design. In most cases, the designer’s work is concerned with adaptation of existing designs. This type of design needs no special knowledge or skill and can be attempted by designers of ordinary technical training. The designer only makes minor alternation or modification in the existing designs of the product.
Development design. This type of design needs considerable scientific training and design ability in order to modify the
existing designs into a new idea by adopting a new material or different method of manufacture. In this case, though the
designer starts from the existing design, but the final product may differ quite markedly from the original product.
New design. This type of design needs lot of research, technical ability and creative thinking. Only those designers who have personal qualities of a sufficiently high order can take up the work of a new design.
The designs, depending upon the methods used, may be classified as follows :
Rational design. This type of design depends upon mathematical formulae of principle of mechanics.
Empirical design. This type of design depends upon empirical formulae based on the practice and past experience.
Industrial design. This type of design depends upon the production aspects to manufacture any machine component in the industry.
Optimum design. It is the best design for the given objective function under the specified constraints. It may be achieved by minimising the undesirable effects.
System design. It is the design of any complex mechanical system like a motor car.
Element design. It is the design of any element of the mechanical system like piston, crankshaft, connecting rod, etc.
Computer aided design. This type of design depends upon the use of computer systems to assist in the creation, modification, analysis and optimisation of a design.
Classification of Engineering Materials
The engineering materials are mainly classified as :
Metals and their alloys, such as iron, steel, copper, Aluminium, etc.
Non-metals, such as glass, rubber, plastic, etc.
The metals may be further classified as :
(a) Ferrous metals, and (b) Non-ferrous metals.
This thesis investigates the shear behavior of externally prestressed concrete T-beams using fiber reinforced polymer (FRP) tendons. An experimental program tested 4 prestressed concrete beams under different shear span-to-depth ratios and prestressing force levels. Test results showed that increasing the prestressing force delayed cracking, increased shear cracking loads, and reduced the number of diagonal cracks. Code equations for predicting shear strength were evaluated against experimental results. The thesis presents analytical methods for calculating shear strength and discusses factors considered in different code equations.
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
Chain sprocket is one of the important component of chain drive for transmitting power from one shaft to another. To ensure efficient power transmission chain sprocket should be properly designed and manufactured. There is a possibility of weight reduction in chain drive sprocket. In this study, chain sprocket is designed and analysed using Finite Element Analysis for safety and reliability. ANSYS software is used for static and fatigue analysis of sprocket design. Using these results optimization of sprocket for weight reduction has been done. As sprocket undergo vibration, modal analysis is performed
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
This document summarizes a study that performed design optimization of a chain sprocket using finite element analysis. The sprocket was first designed and analyzed using ANSYS software for static and fatigue analysis. Based on the results, the sprocket design was optimized for weight reduction while ensuring it remained safe and reliable. The modified design was re-analyzed using static, fatigue, and modal analyses in ANSYS. The analyses confirmed the optimized design had reduced weight and stress while maintaining a sufficient safety factor and fatigue life for use.
The document discusses the design and analysis of a C-clamp using different materials. It analyzes the C-clamp design using both structural steel and aluminum alloy to determine the most suitable material. The analysis includes modeling the C-clamp in ANSYS, applying loads, and evaluating stresses and safety factors. The results show that structural steel performs better with higher safety factors and lower stresses under load compared to the aluminum alloy. Specifically for the handle part, the aluminum alloy shows higher stresses due to greater deflection, making structural steel preferable for withstanding the applied forces in the C-clamp.
This report analyzes and compares an OEM steering tie rod system versus a heim-joint steering system designed and built by students for a 2005 Jeep Wrangler. Finite element analysis was performed on both systems to determine stresses and likelihood of failure. The OEM tie rod was found to fail at 575 lbf of load, while the designed heim-joint system showed stresses well below the yield strength, indicating it would be suitable for the vehicle. The report includes the process, analysis, and conclusions.
ANALYSIS OF CNC LATHE SPINDLE FOR MAXIMUM CUTTING FORCE CONDITION AND BEARING...AM Publications
The present CNC machine structures consist of spindle system which plays a relating to the quality of the
final product and the overall productivity and efficiency of the machine tool itself. The spindle of a CNC lathe
machine, which is rotated by the main motor, holds the cutting tool, which cuts the work piece, so that the cutting
forces are generated which effects the spindle accuracy directly. The forces which are affecting the CNC machine tool
spindle are tangential force (Ft), feed force (Fc), radial force (Fr) and will be estimated. Based on maximum cutting
force incurred the analysis will be carried out. The main objective is to find the static, fatigue analysis of spindle
structure for maximum cutting force condition and predicting life of bearings. From static analysis stress and
deformation of the spindle can be found. Stress obtained from the stress analysis is less than the yield strength of the
material and deformation of the spindle is very less which can be neglected. Equivalent alternating stress, factor of
safety and life of the spindle is found by fatigue analysis and which results are closely matches with the analytical
value
Design, Analysis & Balancing of 5 Cylinder Engine CrankshaftIJMER
This document summarizes the design, analysis, and balancing of a 5 cylinder engine crankshaft. It discusses modeling the crankshaft in Solidworks and analyzing it in ANSYS using finite element analysis. Calculations are shown for designing the crankshaft and crankpin based on engine specifications. Loading and boundary conditions are applied for static structural analysis to determine stresses and deflection. Von Mises and shear stresses from the analysis match theoretical calculations. The conclusions are that finite element analysis is effective for determining permissible stresses and that the 5 cylinder design provides weight optimization and lower cost compared to a 6 cylinder configuration.
Root Fillet Stress Reduction in Spur Gear having UndercutIJLT EMAS
Generally the gear tooth fails due to high stress at root
region. Even a slight reduction in the stress results in greater
increase in life of the gear. For a compact design of a gear box, it
is necessary that the number of teeth of the pinion should be less
.For a given pressure angle there is a limiting value on minimum
number of teeth below which undercut occurs. The spur gear
with undercut suffers in strength severely. Therefore the gears
with undercut are generally avoided. The present work explores
the possibilities of increasing the strength of spur gear having
undercut thereby reduce the overall size of the gearbox. A
systematic study is conducted to understand the effect of
introducing circular stress relief features on stress distribution in
a statically loaded spur gear. Circular stress relief features of
various sizes at different radial distance and angular position are
placed around the end point on critical section on loaded side of
the gear tooth profile. Effect of these stress relief feature on
maximum stress are investigated.
This document summarizes the design, static analysis, and modal analysis of a connecting rod for a four-stroke spark ignition engine using three different materials: structural steel, titanium alloy, and aluminum alloy. The connecting rod was modeled in SolidWorks and analyzed in ANSYS to determine von Mises stresses, shear stresses, deformation, natural frequencies, and safety factors. The results showed that titanium alloy had the highest safety factor and was therefore the best material for withstanding the loads on the connecting rod, though it was heavier than aluminum alloy. Aluminum alloy was the second best choice. Structural steel performed the poorest with the highest weight.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Comparison of Bending Stresses in Involute and Cycloidal Profile Spur Gear ToothIRJET Journal
The document compares the bending stresses in involute and cycloidal profile spur gears using finite element analysis. Gear models with different modules are created in Creo Parametric software and analyzed in ANSYS. The results show that bending stress decreases with increasing module and is lower for involute gears compared to cycloidal gears of the same module. Involute gear teeth experience less bending stress and are stronger than cycloidal gear teeth. The finite element analysis results are slightly different but comparable to values obtained from Lewis equation.
Improving Material Removal Rate and Optimizing Variousmachining Parameters in...theijes
Electric discharge machining is used as machining of electrically conductive hard material. In EDM lots of techniques are applied to improve material removal rate.In this project ‘optimization of machining parameter’ technique is used to improve the MRR in EDM process.There are large number of machining parameters involves in machining the work piece by using EDM process. In this project work an experiment is performed to investigate and optimize the effect of four machining parameters i,e, discharge current, pulse on time, pulse off time,and voltage which is based on Taguchi Design Method.For performing this experiment copper tool (electrode) is used with the ‘mild steel’ workpiece,and kerosene as dielctric fluid has been choosen.Experiment is performed with L9 ORTHOGONAL ARRAY based on Taguchi design method. Signal-to-noise ratio is calculated to investigate the effect of input parameters more accurately.For analysis and explanation,graph is plotted between means of S/N ratio for mrr and four machining parameters ( current.Ton,TOFF, voltage) with the help of MINITAB 17 software.The model have been validated with analysis of variance (ANOVA).I found that discharge current has most significant factor,after that pulse on time,after that pulse off time and voltage has least significant effect
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
OPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USING FINITE ELEMENT METHODijmech
Stress analysis plays an important role in the design of structures like crane hook under loading conditions.
Crane hook is a reliable lifting component being used in industries. Structure failure of crane hook occurs
because of the stress induced due to repetitive loading and unloading conditions. In this study, solid
modeling of crane hook having trapezoidal cross-section referring to one of its existing design is done
using SOLIDWORKS. Further, analyses are carried out in ANSYS Workbench and nCode DesignLife. The
lengths of two parallel sides of the cross-section of crane hook are varied and different candidates are
obtained for loading capacity of 30 ton on the basis of Mass, total Displacement and Von-Mises stress.This
is done to reduce weight and balance economy. Further, out of these candidates, best candidates are
considered and fatigue analysis is performed on these candidates.
Deflection of Dual Rotor Wind Turbine Pinion Tooth by Numerical MethodIRJET Journal
The document discusses a numerical analysis of deflection in the pinion tooth of a dual rotor wind turbine. It begins with an introduction to gears and gearboxes, explaining their importance in mechanical power transmission systems. It then reviews previous literature on gear stress analysis methods. The methodology section describes how CAD software was used to model the pinion gear geometry, which was then imported into finite element analysis software for mesh generation and stress analysis. Results of the finite element analysis are presented, including analytical calculations of the maximum slope and deflection at the free end of the pinion tooth under a tangential force.
IRJET- Review Paper on Design and Stress Analysis of Helical Gear and Man...IRJET Journal
This document provides a literature review and analysis of helical gear design and stresses. It discusses how helical gears are commonly used to transmit power between non-parallel shafts. The review examines previous research on modeling helical gears in ANSYS to analyze contact stresses under varying design parameters like pressure angle, helix angle, and face width. It also explores equations to calculate tooth loads, stresses, and strength. The conclusion is that optimizing factors like contact ratio, gear ratio, helix angle, and face width can enhance gear performance by increasing effectiveness and transmitted power while reducing stresses.
The document describes the development of a robotic manipulator for basic operations in garment manufacturing. Key points:
1) The manipulator is designed to perform pick and place operations to replace human labor in manufacturing.
2) The design includes grippers, modules for X, Y, and Z-axis movement, and controllers for motion and gripper actuation.
3) Kinematic, dynamic, and error analyses were performed to determine motor requirements, ensure accuracy of movements, and compensate for deflection errors.
THE ANALYTICAL STUDY OF MESHING OF DOUBLE HELICAL GEARIJARIIT
The document describes a study analyzing stress in double helical gears using finite element analysis. It discusses previous research on gear stress analysis. The study models two gear stages and performs static structural analysis under specified loads. Results show maximum stress exceeds the material yield strength. The gear geometry is then modified by adding a hole, tapering tooth edges, and adding a groove to reduce stress concentrations. Modified models are re-analyzed to evaluate effect on stress levels.
Objective function to Optimize Bending Stress at Critical Section of Asymmetr...IOSR Journals
Main objective of this paper is to optimize Bending stress at critical section, which is most important
parameter in gear design. It must be low as low possible. Bending Stress optimize by all affected Parameters of
asymmetric spur gear tooth at critical section of tooth. Objective function for bending stress at critical section
has been developed to minimize/optimize bending stress at critical section thickness of asymmetric spur gear
tooth. A programme has been developed in SciLab software with help of developed objective function to
optimize the bending stress at critical section of an asymmetric spur gear. Result obtains from SciLab
programme compared to ANSYS software and give comment on validation of developed objective function
The machine design may be classified as follows :
Adaptive design. In most cases, the designer’s work is concerned with adaptation of existing designs. This type of design needs no special knowledge or skill and can be attempted by designers of ordinary technical training. The designer only makes minor alternation or modification in the existing designs of the product.
Development design. This type of design needs considerable scientific training and design ability in order to modify the
existing designs into a new idea by adopting a new material or different method of manufacture. In this case, though the
designer starts from the existing design, but the final product may differ quite markedly from the original product.
New design. This type of design needs lot of research, technical ability and creative thinking. Only those designers who have personal qualities of a sufficiently high order can take up the work of a new design.
The designs, depending upon the methods used, may be classified as follows :
Rational design. This type of design depends upon mathematical formulae of principle of mechanics.
Empirical design. This type of design depends upon empirical formulae based on the practice and past experience.
Industrial design. This type of design depends upon the production aspects to manufacture any machine component in the industry.
Optimum design. It is the best design for the given objective function under the specified constraints. It may be achieved by minimising the undesirable effects.
System design. It is the design of any complex mechanical system like a motor car.
Element design. It is the design of any element of the mechanical system like piston, crankshaft, connecting rod, etc.
Computer aided design. This type of design depends upon the use of computer systems to assist in the creation, modification, analysis and optimisation of a design.
Classification of Engineering Materials
The engineering materials are mainly classified as :
Metals and their alloys, such as iron, steel, copper, Aluminium, etc.
Non-metals, such as glass, rubber, plastic, etc.
The metals may be further classified as :
(a) Ferrous metals, and (b) Non-ferrous metals.
This thesis investigates the shear behavior of externally prestressed concrete T-beams using fiber reinforced polymer (FRP) tendons. An experimental program tested 4 prestressed concrete beams under different shear span-to-depth ratios and prestressing force levels. Test results showed that increasing the prestressing force delayed cracking, increased shear cracking loads, and reduced the number of diagonal cracks. Code equations for predicting shear strength were evaluated against experimental results. The thesis presents analytical methods for calculating shear strength and discusses factors considered in different code equations.
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
Chain sprocket is one of the important component of chain drive for transmitting power from one shaft to another. To ensure efficient power transmission chain sprocket should be properly designed and manufactured. There is a possibility of weight reduction in chain drive sprocket. In this study, chain sprocket is designed and analysed using Finite Element Analysis for safety and reliability. ANSYS software is used for static and fatigue analysis of sprocket design. Using these results optimization of sprocket for weight reduction has been done. As sprocket undergo vibration, modal analysis is performed
Design Optimization Of Chain Sprocket Using Finite Element AnalysisIJERA Editor
This document summarizes a study that performed design optimization of a chain sprocket using finite element analysis. The sprocket was first designed and analyzed using ANSYS software for static and fatigue analysis. Based on the results, the sprocket design was optimized for weight reduction while ensuring it remained safe and reliable. The modified design was re-analyzed using static, fatigue, and modal analyses in ANSYS. The analyses confirmed the optimized design had reduced weight and stress while maintaining a sufficient safety factor and fatigue life for use.
The document discusses the design and analysis of a C-clamp using different materials. It analyzes the C-clamp design using both structural steel and aluminum alloy to determine the most suitable material. The analysis includes modeling the C-clamp in ANSYS, applying loads, and evaluating stresses and safety factors. The results show that structural steel performs better with higher safety factors and lower stresses under load compared to the aluminum alloy. Specifically for the handle part, the aluminum alloy shows higher stresses due to greater deflection, making structural steel preferable for withstanding the applied forces in the C-clamp.
This report analyzes and compares an OEM steering tie rod system versus a heim-joint steering system designed and built by students for a 2005 Jeep Wrangler. Finite element analysis was performed on both systems to determine stresses and likelihood of failure. The OEM tie rod was found to fail at 575 lbf of load, while the designed heim-joint system showed stresses well below the yield strength, indicating it would be suitable for the vehicle. The report includes the process, analysis, and conclusions.
ANALYSIS OF CNC LATHE SPINDLE FOR MAXIMUM CUTTING FORCE CONDITION AND BEARING...AM Publications
The present CNC machine structures consist of spindle system which plays a relating to the quality of the
final product and the overall productivity and efficiency of the machine tool itself. The spindle of a CNC lathe
machine, which is rotated by the main motor, holds the cutting tool, which cuts the work piece, so that the cutting
forces are generated which effects the spindle accuracy directly. The forces which are affecting the CNC machine tool
spindle are tangential force (Ft), feed force (Fc), radial force (Fr) and will be estimated. Based on maximum cutting
force incurred the analysis will be carried out. The main objective is to find the static, fatigue analysis of spindle
structure for maximum cutting force condition and predicting life of bearings. From static analysis stress and
deformation of the spindle can be found. Stress obtained from the stress analysis is less than the yield strength of the
material and deformation of the spindle is very less which can be neglected. Equivalent alternating stress, factor of
safety and life of the spindle is found by fatigue analysis and which results are closely matches with the analytical
value
Design, Analysis & Balancing of 5 Cylinder Engine CrankshaftIJMER
This document summarizes the design, analysis, and balancing of a 5 cylinder engine crankshaft. It discusses modeling the crankshaft in Solidworks and analyzing it in ANSYS using finite element analysis. Calculations are shown for designing the crankshaft and crankpin based on engine specifications. Loading and boundary conditions are applied for static structural analysis to determine stresses and deflection. Von Mises and shear stresses from the analysis match theoretical calculations. The conclusions are that finite element analysis is effective for determining permissible stresses and that the 5 cylinder design provides weight optimization and lower cost compared to a 6 cylinder configuration.
Root Fillet Stress Reduction in Spur Gear having UndercutIJLT EMAS
Generally the gear tooth fails due to high stress at root
region. Even a slight reduction in the stress results in greater
increase in life of the gear. For a compact design of a gear box, it
is necessary that the number of teeth of the pinion should be less
.For a given pressure angle there is a limiting value on minimum
number of teeth below which undercut occurs. The spur gear
with undercut suffers in strength severely. Therefore the gears
with undercut are generally avoided. The present work explores
the possibilities of increasing the strength of spur gear having
undercut thereby reduce the overall size of the gearbox. A
systematic study is conducted to understand the effect of
introducing circular stress relief features on stress distribution in
a statically loaded spur gear. Circular stress relief features of
various sizes at different radial distance and angular position are
placed around the end point on critical section on loaded side of
the gear tooth profile. Effect of these stress relief feature on
maximum stress are investigated.
This document summarizes the design, static analysis, and modal analysis of a connecting rod for a four-stroke spark ignition engine using three different materials: structural steel, titanium alloy, and aluminum alloy. The connecting rod was modeled in SolidWorks and analyzed in ANSYS to determine von Mises stresses, shear stresses, deformation, natural frequencies, and safety factors. The results showed that titanium alloy had the highest safety factor and was therefore the best material for withstanding the loads on the connecting rod, though it was heavier than aluminum alloy. Aluminum alloy was the second best choice. Structural steel performed the poorest with the highest weight.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Comparison of Bending Stresses in Involute and Cycloidal Profile Spur Gear ToothIRJET Journal
The document compares the bending stresses in involute and cycloidal profile spur gears using finite element analysis. Gear models with different modules are created in Creo Parametric software and analyzed in ANSYS. The results show that bending stress decreases with increasing module and is lower for involute gears compared to cycloidal gears of the same module. Involute gear teeth experience less bending stress and are stronger than cycloidal gear teeth. The finite element analysis results are slightly different but comparable to values obtained from Lewis equation.
Improving Material Removal Rate and Optimizing Variousmachining Parameters in...theijes
Electric discharge machining is used as machining of electrically conductive hard material. In EDM lots of techniques are applied to improve material removal rate.In this project ‘optimization of machining parameter’ technique is used to improve the MRR in EDM process.There are large number of machining parameters involves in machining the work piece by using EDM process. In this project work an experiment is performed to investigate and optimize the effect of four machining parameters i,e, discharge current, pulse on time, pulse off time,and voltage which is based on Taguchi Design Method.For performing this experiment copper tool (electrode) is used with the ‘mild steel’ workpiece,and kerosene as dielctric fluid has been choosen.Experiment is performed with L9 ORTHOGONAL ARRAY based on Taguchi design method. Signal-to-noise ratio is calculated to investigate the effect of input parameters more accurately.For analysis and explanation,graph is plotted between means of S/N ratio for mrr and four machining parameters ( current.Ton,TOFF, voltage) with the help of MINITAB 17 software.The model have been validated with analysis of variance (ANOVA).I found that discharge current has most significant factor,after that pulse on time,after that pulse off time and voltage has least significant effect
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
OPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USING FINITE ELEMENT METHODijmech
Stress analysis plays an important role in the design of structures like crane hook under loading conditions.
Crane hook is a reliable lifting component being used in industries. Structure failure of crane hook occurs
because of the stress induced due to repetitive loading and unloading conditions. In this study, solid
modeling of crane hook having trapezoidal cross-section referring to one of its existing design is done
using SOLIDWORKS. Further, analyses are carried out in ANSYS Workbench and nCode DesignLife. The
lengths of two parallel sides of the cross-section of crane hook are varied and different candidates are
obtained for loading capacity of 30 ton on the basis of Mass, total Displacement and Von-Mises stress.This
is done to reduce weight and balance economy. Further, out of these candidates, best candidates are
considered and fatigue analysis is performed on these candidates.
Deflection of Dual Rotor Wind Turbine Pinion Tooth by Numerical MethodIRJET Journal
The document discusses a numerical analysis of deflection in the pinion tooth of a dual rotor wind turbine. It begins with an introduction to gears and gearboxes, explaining their importance in mechanical power transmission systems. It then reviews previous literature on gear stress analysis methods. The methodology section describes how CAD software was used to model the pinion gear geometry, which was then imported into finite element analysis software for mesh generation and stress analysis. Results of the finite element analysis are presented, including analytical calculations of the maximum slope and deflection at the free end of the pinion tooth under a tangential force.
IRJET- Review Paper on Design and Stress Analysis of Helical Gear and Man...IRJET Journal
This document provides a literature review and analysis of helical gear design and stresses. It discusses how helical gears are commonly used to transmit power between non-parallel shafts. The review examines previous research on modeling helical gears in ANSYS to analyze contact stresses under varying design parameters like pressure angle, helix angle, and face width. It also explores equations to calculate tooth loads, stresses, and strength. The conclusion is that optimizing factors like contact ratio, gear ratio, helix angle, and face width can enhance gear performance by increasing effectiveness and transmitted power while reducing stresses.
The document describes the development of a robotic manipulator for basic operations in garment manufacturing. Key points:
1) The manipulator is designed to perform pick and place operations to replace human labor in manufacturing.
2) The design includes grippers, modules for X, Y, and Z-axis movement, and controllers for motion and gripper actuation.
3) Kinematic, dynamic, and error analyses were performed to determine motor requirements, ensure accuracy of movements, and compensate for deflection errors.
THE ANALYTICAL STUDY OF MESHING OF DOUBLE HELICAL GEARIJARIIT
The document describes a study analyzing stress in double helical gears using finite element analysis. It discusses previous research on gear stress analysis. The study models two gear stages and performs static structural analysis under specified loads. Results show maximum stress exceeds the material yield strength. The gear geometry is then modified by adding a hole, tapering tooth edges, and adding a groove to reduce stress concentrations. Modified models are re-analyzed to evaluate effect on stress levels.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
Adaptive synchronous sliding control for a robot manipulator based on neural ...IJECEIAES
Robot manipulators have become important equipment in production lines, medical fields, and transportation. Improving the quality of trajectory tracking for
robot hands is always an attractive topic in the research community. This is a
challenging problem because robot manipulators are complex nonlinear systems
and are often subject to fluctuations in loads and external disturbances. This
article proposes an adaptive synchronous sliding control scheme to improve trajectory tracking performance for a robot manipulator. The proposed controller
ensures that the positions of the joints track the desired trajectory, synchronize
the errors, and significantly reduces chattering. First, the synchronous tracking
errors and synchronous sliding surfaces are presented. Second, the synchronous
tracking error dynamics are determined. Third, a robust adaptive control law is
designed,the unknown components of the model are estimated online by the neural network, and the parameters of the switching elements are selected by fuzzy
logic. The built algorithm ensures that the tracking and approximation errors
are ultimately uniformly bounded (UUB). Finally, the effectiveness of the constructed algorithm is demonstrated through simulation and experimental results.
Simulation and experimental results show that the proposed controller is effective with small synchronous tracking errors, and the chattering phenomenon is
significantly reduced.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
K8sGPT is a tool that analyzes and diagnoses Kubernetes clusters. This presentation was used to share the requirements and dependencies to deploy K8sGPT in a local environment.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
2. Presentation OutlinePresentation Outline
Introduction: What is Machine Design?Introduction: What is Machine Design?
Machine Design: Research AreasMachine Design: Research Areas
Research Applications:Research Applications:
– Gear Tooth FEM/FEA and Optimization
– Machine Design Optimization
– Customized Knee Implant: Design, Stress
Analysis and Manufacturing
3. Introduction:Introduction:
What is Machine Design?What is Machine Design?
Core of mechanicalCore of mechanical
engineeringengineering
– Stress and strain
– Designing for safety
– Static failure theories
– Fatigue failure
theories
– Machine elements
– Mechanical material
properties
– Stress
Concentrations
– Fracture Mechanics
– Optimization
– Composite Materials
– Manufacturing
Processes
– Computer Aided
Machine Design and
Analysis
– Measuring Stress
and Strain
4. Stress and strainStress and strain
– Normal stresses and strains
– Shear stresses and strains
– Principal stresses and strains
– Mohr’s circle and analytical relationships
Introduction: Stress and StrainIntroduction: Stress and Strain
τ
σ
σ1σ2σ3
22
2,1 )
2
(
2
xy
yxyx
τ
σσσσ
σ +
−
±
+
=
22
max )
2
( xy
yx
τ
σσ
τ +
−
±=
yx
xy
σσ
τ
θ
−
=
2
)2tan(
θ σx
σy
τxy
5. Introduction: Static FailureIntroduction: Static Failure
Ductile BehaviorDuctile Behavior
– Maximum Shear-Stress Theory
(Tresca/Coulomb/Guest Theory)
– Distortion Energy Theory (von Mises)
Brittle Behavior (even and uneven materials)Brittle Behavior (even and uneven materials)
– Coulomb-Mohr Theory
FS
S
σσ
y
31 ≤−
FS
S
)σ(σ)σ(σ)σ(σ
2
2
σ
y2
13
2
32
2
21eff ≤−+−+−=
σ
τ
Compression
test Tension
test
σ1
σ3
Sut,Sut
Sut,-Sut
Sut,-Sut
-Sut,Sut-Suc,Sut
uneven
6. Introduction: Fatigue FailureIntroduction: Fatigue Failure
Alternating and mean stressAlternating and mean stress
Stress-Life ApproachStress-Life Approach
– High Cycle Fatigue Criteria
– Load amplitude is consistent
– Common for rotating machinery
Strain-Life ApproachStrain-Life Approach
– Low cycle fatigue (<103
)
– Variations in loads and high
temperatures
– Common for service machinery
Fracture MechanicsFracture Mechanics
ApproachApproach
– Low cycle fatigue
– Generally used to determine
remaining life of a cracked part
– Paris equation n
KA
dN
da
)(∆⋅= n,A: empirical values
K: stress intensity factor
σ
t
103
104 106
107
105
1.0
0.6
0.8
0.4
Corrected endurance limit:
Se
=Cload
Csize
Csurf
Ctemp
Creliab
Se‘
Corrected fatigue strength
Sf
=Cload
Csize
Csurf
Ctemp
Creliab
Sf'
8. Machine Design:Machine Design:
Research AreasResearch Areas
Finite Element AnalysisFinite Element Analysis
Design OptimizationDesign Optimization
BiomechanicsBiomechanics
NanotechnologyNanotechnology
Fracture MechanicsFracture Mechanics
Mechanical Material PropertiesMechanical Material Properties
Composite MaterialsComposite Materials
Designing for ManufacturingDesigning for Manufacturing
WeldingWelding
9. Research Applications:Research Applications:
Gear tooth stress analysis and measurementGear tooth stress analysis and measurement
– Typical component studied in machine design
Finite element modeling and analysis
Stress measurement using polariscope
Machine Design OptimizationMachine Design Optimization
– Improve performance, reduce mass, stress and
cost
Missile design
Optimization theory
Customized Knee Implant:Customized Knee Implant:
– Hinge joint
Design to even out stress, remove areas of stress
concentration
Finite element analysis
Manufacturing
10. Gear Tooth: IntroductionGear Tooth: Introduction
Gear is a typical component studied in machine designGear is a typical component studied in machine design
In analyzing the stresses in gears one uses stress/strainIn analyzing the stresses in gears one uses stress/strain
and failure theoriesand failure theories
The stresses were measured using a polariscopeThe stresses were measured using a polariscope
Objective:Objective: minimize stress at the root of a gear tooth byminimize stress at the root of a gear tooth by
introducing a stress relief holeintroducing a stress relief hole
Parameters: location (r,Parameters: location (r, θ)θ) and size of holeand size of hole
Analytical model: I-DEAS Master SeriesAnalytical model: I-DEAS Master Series
– Solid Model, FEA, Optimization, .stl file
Experimental analysis to validate analytical model
– Stereolithography model, Polariscope
13. Gear Tooth: Solid Model CreationGear Tooth: Solid Model Creation
Involute and gear created in I-DEASInvolute and gear created in I-DEAS
Simplifications: no fillets, one toothSimplifications: no fillets, one tooth
– Pitch Diameter = 360 mm
– Number of teeth = 30
– Pressure angle = 20o
– Addendum = 12 mm
– Dedendum = 15 mm
– Gear thickness = 5 mm
– Circular tooth thickness = 18.85 mm
14. Gear Tooth: FEAGear Tooth: FEA
Results: original modelResults: original model
– Band of high max principal stress
– Max tensile stress
– Area of concern
Crack propagation
Fatigue failure
begins at a crack
Load
Max
Tensile
Stress
15. Gear Tooth: FEAGear Tooth: FEA
MeshMesh
– Triangular shell elements
– With and without hole
– Partitions
– Free locals – mesh control
Boundary conditionsBoundary conditions
– Cantilever beam approx.
Load: along 20Load: along 20oo
pressurepressure
lineline
17. Gear Tooth:Gear Tooth: Optimized HoleOptimized Hole
LocationLocation
θ=29o
r = 4 mm
diameter =2 mm
18. Gear Tooth: StereolithographyGear Tooth: Stereolithography
Model CreationModel Creation
Stereolithography machine SLA-250Stereolithography machine SLA-250
–Laser cured one layer at a time
–Thickness: 0.006 inch (103
layers)
–Material: SL5170
–Ultraviolet oven for 45 min
Models created in 15 hoursModels created in 15 hours
–With and without hole
20. Gear Tooth: ExperimentalGear Tooth: Experimental
SetupSetup
Experimental study to verify FEAExperimental study to verify FEA
A flange with holes for mounting wasA flange with holes for mounting was
added to the models to hold the parts inadded to the models to hold the parts in
place in the polariscopeplace in the polariscope
– Compression force was applied
– Bracket was used to distribute the force
Circular polariscope dark fieldCircular polariscope dark field was usedwas used
– Used to analyze stress in 2D models
22. Gear Tooth: Isochromatic FringesGear Tooth: Isochromatic Fringes
Extinction of light of a particular wave lengthsExtinction of light of a particular wave lengths
(colored light)(colored light)
Determines the magnitude of the stressDetermines the magnitude of the stress
differencedifference
– n = hc/λ*(σ1- σ2)
n: fringe order
hc/λ: constants
σ1- σ2: stress difference
black yellow red | blue yellow red | green yellowblack yellow red | blue yellow red | green yellow
red | green yellow red | g y r | ...red | green yellow red | g y r | ...
23. Gear Tooth: Comparison ofGear Tooth: Comparison of
Fringes With and Without HoleFringes With and Without Hole
26. Gear Tooth:Gear Tooth:
Concluding RemarksConcluding Remarks
Stresses were analyzed and measured for a gearStresses were analyzed and measured for a gear
– Stresses decreased by 15%.
– Deflection increase of 2.3% has no major effect on the
kinematics and functionality of gear.
Hole was introduced close to the corner ofHole was introduced close to the corner of
maximum tensile stress at an angle of 29 degreesmaximum tensile stress at an angle of 29 degrees
from vertical.from vertical.
Photoelasticity results verified the analysisPhotoelasticity results verified the analysis
27. Designing parts for performance and massDesigning parts for performance and mass
productionproduction
– Mass reduction
– Stress reduction
– Cost reduction
– Performance improvement
– Machine design components or systems
Missile designMissile design
– Optimization theory and application
– Academic vs. industrial design optimization
Machine Design Optimization:Machine Design Optimization:
Optimization of a MissileOptimization of a Missile
28. Machine Design Optimization: BasicsMachine Design Optimization: Basics
Optimization VocabularyOptimization Vocabulary
Minimize F(X) Objective function
s.t. gj
(X) ≤ 0Inequality
hk
(X) = 0 Equality constraints
Xi
lower
≤ Xi
≤ Xi
upper
Side
X Design variable vector
Multidisciplinary Design OptimizationMultidisciplinary Design Optimization
– Computational expense
– Organizational complexity
DescriptionDescription
11 Aerodynamic configurationAerodynamic configuration
mass propertiesmass properties
CG locationCG location
22 Aerodynamic coefficientsAerodynamic coefficients
33 Thrust verses timeThrust verses time
Specific ImpulseSpecific Impulse
Nozzle dimensionsNozzle dimensions
44 DimensionsDimensions
Volume, MassVolume, Mass
ConfigurationConfiguration
55 Nozzle exit diameterNozzle exit diameter
power on/offpower on/off
66 Geometric dimensionsGeometric dimensions
Propulsion dimensions,Propulsion dimensions,
Material, WeightMaterial, Weight
77 Single or dual pulseSingle or dual pulse
configurationconfiguration
Propellant weightPropellant weight7
6
4
Propulsion
Analysis
Cost Analysis
Aerodynamic
Analysis
Trajectory
Analysis
1
2
3
5
Geometry
Engine
29. Machine Design Optimization: BasicsMachine Design Optimization: Basics
Optimization AlgorithmsOptimization Algorithms
– Gradient-based Algorithms
– Genetic Algorithms
MDO FormulationsMDO Formulations
– Discipline communication
ApproximationsApproximations
– Artificial Neural Networks
– Design of Experiment
– Response Surface Approximations
– Taylor Series Approximations
30. Machine Design Optimization: AlgorithmsMachine Design Optimization: Algorithms
Gradient BasedGradient Based
– Sensitivities (gradients)
from finite difference
– Local minimum
– Basic concept
Xq
= Xq-1
+ α*
Sq
X: design vector
q: iterate
S: Search direction
α: distance to move in direction S
– Unconstrained problem
Gradient is zero
Positive definite Hessian Matrix
– Constrained problem
Khun-Tucker necessary condition
X*
is feasible
λjgj (X*
) = 0 j = 1,m λj ≥0
∇F(X*
) + Σλj∇gj(X*
) + Σλk∇hk(X*
) = 0
λj ≥0
x
)()(
∆
−∆+
=
∆
∆ xuxxu
x
u
31. Machine Design Optimization:Machine Design Optimization:
Academic vs.Academic vs. IndustrialIndustrial ProblemsProblems
Design GoalDesign Goal
– Maximize range
Key designKey design
parametersparameters
– Mid body diameter
– Mid body length
– Nose length
– Case length
– Web fraction (difference of
the outer and inner radii to the
inner radius)
– Expansion ratio (the ratio
of the exit area to the throat area
of the nozzle)
– Gamma (angle of the
velocity vector)
ConstraintsConstraints
– Weight
– Center of gravity
– Total missile length
– Cost
– Nose finess ratio
– Minimum Mach number
32. Machine Design Optimization:Machine Design Optimization:
Missile Concluding RemarksMissile Concluding Remarks
Algorithms, Formulations, Approximations andAlgorithms, Formulations, Approximations and
programming language were combined to removeprogramming language were combined to remove
obstacles.obstacles.
Optimization scheme was integrated and tested on aOptimization scheme was integrated and tested on a
highly coupled air-to-air sparrow-like missilehighly coupled air-to-air sparrow-like missile
– Efficient and robust optimization scheme:
Reduced computational time up to 44%
Allows for modifications to the optimization statement
Covers regions in the design space for which a response
cannot be computed
Scheme can be applied to other large-scaledScheme can be applied to other large-scaled
engineering problemsengineering problems
33. Knee Implant Example cKnee Implant Example c
Knee joint is a hinge jointKnee joint is a hinge joint
Stress analysisStress analysis
Stress concentrationsStress concentrations
Wear of the implantWear of the implant
ManufacturingManufacturing
– Rapid Prototyping
– Investment Casting
Tibia
Fibula
Femur
Patella
34. Knee Implant Example:Knee Implant Example:
Need for CustomizationNeed for Customization
>0.5 million orthopedic implant surgeries conducted>0.5 million orthopedic implant surgeries conducted
each year in the USeach year in the US
– Number increasing
Increasing life span
Higher activity level
Problems associated with implants are proportionallyProblems associated with implants are proportionally
increasingincreasing
– Use of standard implants leads to removal of valuable bone
material
– Revisions are primarily due to loosening of implants
Poor fit – only a few types and sizes are available
Stress concentrations affect bone remodeling
35. Knee Implant Example:Knee Implant Example:
Current DesignCurrent Design
Cancellous
Bone
Cortical
Bone
Tibial
PlateauStem
Sharp edges
Medial cross section of
femoral component
36. Knee Implant Example:Knee Implant Example:
Current DesignCurrent Design
PProblems with current design:roblems with current design:
– Only 7 different sizes
– Removal of bone
– Doesn’t fit perfectly
– Not used for younger patients
– Sharp edges
– Stress concentrations
– Bone remodeling
– Loosens with time
Tibial component
Femoral component
37. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Designing the customized implantDesigning the customized implant
– Implant should resemble the geometry of the
original knee
– Redistribution of stresses results in variation of
bone mineral density
– Reduce possible relative motion of tibial plate
implant to the tibial bone
Data acquisitionData acquisition
– Computed Tomography data
Modeling of bone and implantModeling of bone and implant
38. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
CT-data acquisitionCT-data acquisition
– Scanning device completes a 360o
revolution
– Slices are 1 to 5 mm apart
– Result: Matrix with gray scaled pixels based on
tissue density
39. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Data conversion using Mimics fromData conversion using Mimics from
MaterialiseMaterialise
Density threshold
Investigation of each scanned slice
40. Scanning the objectScanning the object
Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Slice distance
Resulting Image SetResulting Image Set
41. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Select the desired regionSelect the desired region
…… and Growand Grow
42. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Data conversion using Mimics from MaterialiseData conversion using Mimics from Materialise
43. Knee Implant Example:Knee Implant Example:
Design of Customized ImplantDesign of Customized Implant
Femoral Component Tibial Component
44. Knee Implant Example:Knee Implant Example:
Initial Stress Analysis of ImplantInitial Stress Analysis of Implant
Finite Element AnalysisFinite Element Analysis
– 0o
, 45o
,90o
gait angle
– Load 3,5,10 times the body weight
45. Knee Implant Example:Knee Implant Example:
Initial Stress Analysis of ImplantInitial Stress Analysis of Implant
46. Knee Implant Example:Knee Implant Example:
Initial Stress Analysis of ImplantInitial Stress Analysis of Implant
45o
gait
90o
gait
48. Knee Implant Example:Knee Implant Example:
ManufacturingManufacturing
Rapid PrototypingRapid Prototyping
–Laser cures one layer at a time
–Thickness: 0.006 inch
Investment CastingInvestment Casting
CAD model to stereolithographyCAD model to stereolithography
modelmodel.
–Eliminates costly low-production-
run wax pattern tooling.
52. Knee Implant Example:Knee Implant Example:
Concluding RemarksConcluding Remarks
An implant design has been studied andAn implant design has been studied and
redesigned to increase life of the implantredesigned to increase life of the implant
Initial stress analysis have been performed.Initial stress analysis have been performed.
– Results are favorable for the new implant
Manufacturing of implantManufacturing of implant
– Rapid prototype model
– Investment casting model
Future work:Future work:
– Improve finite element model and analysis
– Parameterize and optimize
Machine design:Machine design:
– Hinge joint, stress analysis, stress concentration,
wear, manufacturing
53. Overall ConclusionOverall Conclusion
Machine Design OverviewMachine Design Overview
Research Areas and ApplicationsResearch Areas and Applications
– Gear Tooth FEM/FEA and Optimization
– Machine Design Optimization
– Customized Knee Implant: Design, Stress
Analysis and Manufacturing
Research Mission at UNFResearch Mission at UNF