Finite Element Analysis (FEA)

An All-Terrain Vehicle is an Off Road vehicle that has the ability to drive on any terrain
without any difficulty. These vehicles are designed to sustain any sort of extreme loads that act
during off road driving. All-Terrain Vehicles are fitted with large tires with grooves for better
traction on slippery terrains, high ground clearance to avoid obstacles, and usually designed with
high torque rather than speed. As compared to commercial vehicles, these vehicles are designed
to be more strong and durable. These vehicles are vastly used in Deserts, Mountains, forests or any
other gravel surfaces.
All-Terrain Vehicles are vastly used in farming in India. Best examples are tractors and
snow mobiles. The main key for such vehicles is the powertrain assembly which is unique and
differs from other vehicles. The power train includes Engine, Manual Gearbox, Limited slip
Differential or in some cases a reduction gearbox coupled with a continuously Variable
Transmission (CVT).CVT is the new technology being implemented in Off Road Racing.
BAJA vehicles are the most famous Off Road Vehicles in India.However,due to the
extreme loads caused by the gravel tracks and the constraints to reduce the weight, one major
component is susceptible to failure—Reduction Gearbox. Gearbox is a costly component and on
failure, the vehicle is immobile The Power Train assembly is so complicated that it occupies a lot
of space in the vehicle hence increasing the overall weight. The aim of this project is to design a
gearbox that is compact, lightweight and has extended life. Major fields covered are Material
selection, Machine Engineering Design of Gears, Shafts, Gearbox Casing, Bearing selection,
Vibrations caused due to the Engine. These analytical designs have been validated through the
help of CAD and FEA software like SolidWorks and ANSYS. Various Analysis like Structural,
Repeated loads and Computational Fluid Dynamics (CFD) have been performed to study the
behavior of components and oil flow during operations. The design is also finalized with the fits
required for assembly and the final product is expected to be efficient, light weight, compact and
long lasting than the other Gearboxes being used today.
Keywords: All-Terrain Vehicle, Reduction Gearbox, Computer Aided Engineering (CAD),
Computational Fluid Dynamics (CFD), Vibrations, Finite Element Analysis (FEA)

Conventional mechanism (i.e. rigid link mechanisms) has limited accuracy and repeatability because of friction, backlash. Mechanism offers a relative motion between rigid links via joints. Conventionally these joints are pin, sliding, rolling, liquid film etc. These joints have inherent nonlinear frictional characteristics which are creating difficulty in control micro-nano positioning in precision mechanisms. To achieve high resolution and precision problems of friction, backlash in mechanism needs to be removed. These joints are replaced by flexible elements such as flexural hinge, flexural links which offers advantage of frictionless and smooth motion. Flexural mechanisms are developed using basic building blocks such as hinges and planar type. Flexural building blocks should be such that it offers lesser / zero resistance to motion in desired direction and maximum / infinite resistance in orthogonal direction. Motion generated in orthogonal direction is called parasitic motion. Double Flexural Manipulator (DFM) is a planar type building block which offers theoretically zero parasitic error motion with negligible amount of rotation of motion stage. This article presents design, development, system integration, system identification and PID control implementation on DFM. Developed flexural stage is integrated with desktop PC via dSPACE micro-controller. System identification (Static and Dynamic) is carried out and performance parameters such as stiffness, natural frequency, damping characteristics and frequency characterization of DFM are estimated and validated via due experimentations. Estimated transfer function of DFM is further used for development of control system, and PID control parameters are tuned. Real time PID implementation gives a position accuracy of few microns at high scanning speed of 2.5 mm/s.

Selective laser melting (SLM) is an additive technology that allows for the production of precisely designed complex structures for energy absorbing applications from a wide range of metallic materials. Geometrical imperfections of the SLM fabricated lattice structures, which form one of the many thin struts, can lead to a great difference in prediction of their behavior. This article deals with the prediction of lattice structure mechanical properties under dynamic loading using finite element method (FEA) with inclusion of geometrical imperfections of the SLM process. Such properties are necessary to know especially for the application of SLM fabricated lattice structures in automotive or aerospace industries. Four types of specimens from AlSi10Mg alloy powder material were manufactured using SLM for quasi-static mechanical testing and determination of lattice structure mechanical properties for the FEA material model, for optical measurement of geometrical accuracy, and for low-v...

A New Product Introduction and Development process is one of the Corner stone's towards a competitive advantage in any market place today. A fully optimised process in combination with other lean and agile manufacturing techniques and systems is guaranteed to reduce lead-time and save on cost. New product development is a means for a company to gain advantage, secure a position, or win a new customer. The more successful and timely an organization can develop new products, the more likely it is that organization will not only survive but prosper.  As suggested by review of the literature's and studies, there are several factors that significantly affect a product's chances of succeeding or failing. Many of these factors are associated with resources resulting from marketing activities that integrate the user/customer needs into the process. There is a significant amount of research that indicates that Conducting early stage marketing activities greatly improves the likelihood of new product success, yet the deficiency of these activities is one of the most commonly stated reasons for product failure by New Product Development members.

The model of inclined seam excavation is established acc ording to the deformation characteristics of inclined seam and the principles of FEA. It carried out numerical s imulation method to research rock mass movement, surface subsidence and distribution of stress, which simulated excavat ion with the ANSYS software, at the same time the basi c characteristics of rock movement and the correlative par ameters of surface subsidence are obtained. The ANSYS software can not only compute the deformation mechanism of surface subsidence, but also draw up the distribution contours of stress, the distribution contours of horizontal displace and vertical subsidence. The computing model visuall y displays the deformation and stress distribution of the o verburden rock board, coal strata and lower rock board. The deformation mechanism of surface subsidence provides a refe rence for inclined seam excavation under the building. The underground excavation of mine is the huge and complex system eng...

Two original numerical techniques are developed for the finite element (FE) transient analysis of induction and permanent magnet motors operating in demanding aerospace applications. The first technique is the electromagnetic and thermal analysis weak coupling using a multiple slices 2D FE model. The advantage of the specific technique is the representation of complex actuator geometries including skewed magnets and winding ends, by using a low computational cost 2D model while taking into consideration temperature dependent material attributes. The second technique consists in the development of properly defined boundary conditions for the emulation of the cooling housing of actuators. Those boundary conditions are applied at the outer surface of the actuators in contact with the housing and eliminate the need of modeling complex 3D geometries of highly integrated actuator housings.

Plastic electronic packages are known to absorb moisture when exposed to humid ambient conditions during storage in tape and reel in the factory. Reliability becomes a concern when packages are exposed to a humid environment for a prolonged time and then processed through a reflow oven. Thermo-mechanical and moisture induced interfacial stresses generated between the die attach and die may

Aiming at the complex modal characteristic of the frame of the light electric sanitation vehicle under various working conditions, the finite element method is used to study the natural frequency and modal shape cloud diagram. Based on the frame model established in the three-dimensional software, the model characteristic is analyzed, the natural frequency and modal shape of the first five orders of mode are obtained, and their influences on vehicle travel are analyzed. The frame is improved, and the influence of the improved frame on the natural frequency and modal shape are analyzed. The results show that the bending and torsion resistance of the improved frame is ameliorated. Compared with the torsion resistance, the bending resistance of the frame is much ameliorated, which lays a foundation for the relative experiment, dynamics analysis and structural improvement of the frame.

Abstract Sauropod dinosaurs were the largest terrestrial
herbivores and pushed at the limits of vertebrate biomechanics
and physiology. Sauropods exhibit high craniodental
diversity in ecosystems where numerous species coexisted,
leading to the hypothesis that this biodiversity is
linked to niche subdivision driven by ecological specialisation.
Here, we quantitatively investigate feeding behaviour
hypotheses for the iconic sauropod Diplodocus. Biomechanical
modelling, using finite element analysis, was used to
examine the performance of the Diplodocus skull. Three
feeding behaviours were modelled: muscle-driven static biting,
branch stripping and bark stripping. The skull was found to be
‘over engineered’ for static biting, overall experiencing low
stress with only the dentition enduring high stress. When
branch stripping, the skull, similarly, is under low stress, with
little appreciable difference between those models. When simulated for bark stripping, the skull experiences far greater
stresses, especially in the teeth and at the jaw joint. Therefore,
we refute the bark-stripping hypothesis, while the hypotheses
of branch stripping and/or precision biting are both
consistent with our findings, showing that branch stripping
is a biomechanically plausible feeding behaviour
for diplodocids. Interestingly, in all simulations, peak
stress is observed in the premaxillary–maxillary ‘lateral
plates’, supporting the hypothesis that these structures
evolved to dissipate stress induced while feeding. These
results lead us to conclude that the aberrant craniodental
form of Diplodocus was adapted for food procurement
rather than resisting high bite forces.

A generalized macroscopic representation of electrical steels used in transformer manufacturing industry is developed. The proposed representation is specifically formulated for integration in the finite element method. Usage of the specific technique enables the accurate evaluation of electromagnetic field distribution of transformer cores under heavily saturated conditions. Advantages over conventional techniques include numerical stability, numerical accuracy, and reduction of iterations of the Newton–Raphson method.

The objective of this study is to determine the optimal cooling scheme to minimise the processing time during the cooling stage in press moulding. The optimisation is subject to the quality constraints concerning maximum allowable residual stress and recommended levels of crystallinity. Since they depend on temperature state, a one-dimensional transient heat transfer analysis was carried out using a finite difference method so as to obtain the transient temperature profile through the thickness of the laminate. The heat transfer analysis was then coupled with a crystallisation-kinetics model. Using a plane-strain viscoelastic model, residual stress distribution was obtained corresponding to a given cooling scheme. These models were then integrated into an optimisation algorithm called sequential simplex, to minimise the cooling time without compromising quality requirements. Significant reduction in processing time was obtained for APC-2 laminates

Bogie is a unity that supports the construction of railway facilities monorail when running on the track. Bogie frame is a construction to support the carbody against imposition. The purpose of this analysis is to determine and ascertain the limits static strength numerical order before the prototype bogie frame through static testing or verification stage design. Stages in this research is the collection of data and bogie drawing APMS of PT.INKA Madiun, and then to identify the 3D CAD model of the structure of the bogie frame, then conducted to determine the boundary conditions for the imposition of simulated static load.Base on standard UIC-615 there are only two types of load that is vertical and transversal, the maximum value is 53 234 and 48 619 N. Result of static testing for static tests with exceptional load, the greatest deformation of 0.5 mm occurs on the balanced wheel, and a maximum stress of 175,97 MPa which lies in the foundation of anti-roll bar, due to transverse load occurring on the pedestal of the anti-roll bar is quite large. Safety factor value that occurs in the area of anti-roll bar is quite low, 1,39.The simulation results for the static testing workload (Static test to Simulate the main in-service load) obtained value of the lowest safety factor of 2.39 with a maximum stress value of 102.26 MPa and deformation of 0,339 mm at the time of load case 8.

In this paper a robust three-dimensional (3D) finite element (FE) anisotropy model is introduced based on a particular scalar potential formulation. The specific 3D FE model is suitable for the accurate evaluation of the peak flux density distribution and no load loss of one-phase and three-phase wound core distribution transformers. The accuracy of the proposed 3D FE anisotropy model is validated by local flux density and no load loss measurements.

This work is carried out on a mono parabolic leaf spring of a mini loader truck, which has a loading capacity of 1 Tonnes. The modelling of the leaf spring has been done in CATIA V5 R20. And for finite element analysis the model was imported in the static structural analysis workbench of CATIA V5 R20. The finite element analysis of the leaf spring has been carried out by initially discretising the model and then applying the relevant boundary conditions. Max Von Mises stress and Max Displacement are the output parameters of this analysis. In order to study the behaviour of parabolic leaf spring, Design of experiments has been implemented. In DOE, input parameters such as Eye Distance & Depth of camber have been varied and their affect on output parameters have been plotted.

There have been numerous publications on unreinforced masonry construction in the literature; however, there is a lack of publications on the condition assessment of existing unreinforced masonry façades for disturbances due to nearby subway construction. To fill this gap, this paper presents a study in which a 5-story historical building with unreinforced masonry façade experiences inward and outward deformations perpendicular to the plane of wall due to nearby subway construction. The performance of the unreinforced masonry façade is examined under wind load combinations. For this, a finite-element (FE) model is built in ANSYS software to conduct a stress analysis of the brick façade. The results revealed that the tensile stresses exceeded the tensile stress limit at several locations; therefore, a structural remediation is required. A structural retrofit is proposed to tie the façade wall to the floor diaphragms with steel anchor rods at specific stories. Another FE model is built to represent the remedies proposed for stabilizing the façade wall. The results show that all stresses are within the limits, indicating that the structural solution for the remediation is appropriate. As a result of this study, the proposed remediation was implemented at the building, and the structure has been in good structural condition without any complaints, even after the subway construction was completed and the subway line was in operation.

PurposeThe purpose of this paper is to propose a new outer‐rotor permanent‐magnet flux‐switching machine (ORPMFSM) for electric vehicle (EV) in‐wheel propulsion. The paper documents both the design procedure and performance investigation of this novel machine.Design/methodology/approachThe topology and preliminary sizing equations of the ORPMFSM are introduced. The rotor poles are optimized, whilst the machine losses are particularly investigated, using 2‐D finite element analysis (FEA).FindingsAn ORPMFSM, with 12 stator poles and 22 rotor poles, is most suitable for the proposed EV application. The analytical sizing equations are quite efficient with a sufficient accuracy for the preliminary design. The optimal rotor pole width from the FEA results is nearly 1.3 times the original value which was proposed in early literatures. The efficiency of the proposed machine under rated load is slightly low, as a result of significant eddy current losses in the permanent magnets. The losses ...

It is very difficult to follow and to understand all rheological events in the tool cavity and the influence of
parameters during the process that they have on the properties of components during the injection phase. To
understand the injection phase it is necessary to use numerical simulations. The advantage of using FE
simulation is verification of the fulfillment of construction of components and the tools, and comparison and
adjustment of the various combinations of parameters before the start of the process. A lack of application of
simulation is thet the FE code can't simulate effects such as segregation, accumulation of the metal powder
particles and the appearance of separation of metal powder and binder. The work showed simulation and real
experiment with a review and variation of parameters: the speed of injection, temperature of tools and profile
of pressure with the goal to predict the filling of tool cavity and distribution of pressure.
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Reološka zbivanja unutar alatne šupljine te uticaj parametara procesa na svojstva komponente tokom faze
injektiranja je veoma teško pratiti i razumjeti. Za razumijevanje faze injektiranja neophodno je koristiti
numeričke simulacije. Prednost korištenja FE simulacije je provjera i zadovoljavanje konstrukcije
komponente i alata te usporedba i podešavanje različitih kombinacija parametara prije samog pokretanja
procesa. Nedostatak primjene simulacija je što FE kod ne može simulirati efekte kao što su segregacija,
nagomilavanje čestica metalnog praha te pojave razdvajanja metalnog praha i veziva. U radu je sproveden
simulacijoni i realni eksperiment uz razmatranje i varijaciju parametara: brzine injektiranja, temperature
alata i profila pritiska držanja s ciljem predviđanja popunjavanja alatne šupljine te raspodjele pritisaka.

Currently, the gantry crane in LAPAN Garut still uses steel material. The steel material is protected using a coating to minimize the impact of corrosion. However, this method is less efficient, considering the corrosion rate in LAPAN Garut is very high because it is located on the coast of Cilauteureun. It also creates problems in terms of maintenance because it has to be done regularly and periodically repainting. In addition, not all equipment is available maintenance funds every year. The objective of this paper is to design and analyze the stress of a gantry crane with a capacity of 9 tons using Aluminum 6061 material. The material used is three units of JIS G 3192 H standard frame (I-shape) with a size of 150 x 150 x 7 mm, four units of JIS G 3466 frame (square profile) with a size of 150 x 150 x 6 mm, and four units of JIS G 3466 frame (square profile) with a size of 125 x 125 x 6 mm. Finite element analysis is performed using Autodesk Inventor Professional 2017 software. The simulation results show that the gantry crane has a mass, von Mises stress, deformation, and safety factors respectively at 165.36 kg; 132.9 MPa; 13.67 mm; and 2.07.

Computer Aided Design (CAD) and Computer Aided Engineering (CAE) is the most important and essential tool in product development process. Huge challenge is faced by the companies while integrating CAD and CAE in their design process. The previous studies do not clearly give the impact of CAD and CAE on product development process and particularly its impact on cost and time of development. The study is carried out to show the importance of CAD and CAE as a tool of product development and its effect on the development cost and time when implemented early in the process.

Controlling seismic damage and improving performance are creative ideas of earthquake designing in which uses definite demonstrating of the structure together with techniques. One of the most important tools to dissipate energy is dampers that are able to reduce vibrations. Especially Fluid Viscous dampers (FVD) which are used to investigate the response of Reinforced Concrete building when they are subjected to lateral load like seismic. A structure might be viewed as serviceable in the event where it can be satisfied by transferring loads to foundation. Since earthquake loads are imposed on a structure, vibrations occur. To resist responses and absorb energy, Fluid Viscous Dampers is used. With Equivalent Static, Response Spectrum and Time history method, it is vital to identify characteristics by (ETABS) finite element program where Models having ordinary RC moment-resisting frame by square column cross-sections with and without FVD. In this evaluation, it is utilized in linear and non-linear analysis where ETABS, Version (18.0.2), has been used. The results are shown that dampers (FVD) dramatically reduce the lateral deflection and enhance the performance of the structure. They also cause a decrease in Time period of maximum Psuedo Spectral Acceleration (PSA) in Response spectrum curves, increasing the story stiffness and decreasing the story Shear. Therefore, adding FVD to RC buildings is effective utilization due to its dissipation of energy.

Finishing of Additively Manufactured (AM) components is crucial for endowing them with fatigue resistance. Unfortunately, current AM processes naturally promote anisotropic surface characteristics that make it challenging to optimize finishing processes. In this study, bead blasting is explored as a process for finishing Electron Beam Melted (EBM) Ti-6Al-4V. Effects of anisotropic roughness characteristics on mechanics of bead blasting are delineated using surface texture measurements via optical profilometry and residual stress measurements via X-Ray Diffraction (XRD). As-received surfaces resulting from AM as well as those in Electrical Discharge Machined (EDM) are studied. It is seen that pre-processed roughness textures heavily influence final textures and residual stresses. These linkages are quantified using plasticity index as the governing metric-a rougher surface features a larger plastic index which results in comparatively greater evolution of its texture characteristics than a smoother surface after equivalent bead blasting treatments. The mechanics of this evolution are delineated using energy-controlled indentation as a model representing a single impact in bead blasting. It is seen that rougher surfaces featuring complex textures in as-received states also produce complex stress states featuring a greater level of locally tensile stresses during indentation compared with smoother surfaces. Approaches to address these complications are proposed that can potentially transform a printed, non-functional surface into one that is optimized for fatigue resistance.

The design of vertical tail structure varies according to nature of aircraft and its function. The experimental test of vertical tail structure is difficult and more expensive process. In this present work detailed design of transport aircraft vertical tail with rudder structure modelling done by using CATIA V5 R19 software. The static stress analysis is carried out to find the stresses at of the vertical tail with rudder structure for different deflection of rudder. The stresses are estimated to find the safety factor of the structure using finite element approach with the help of MSC/PATRAN and MSC/NASTRAN software. The material used in the vertical tail structure is aluminium 7075-T6, which has high fatigue strength. From the analysis it is found that maximum principal stress of vertical tail structure is less than yield strength of aluminium 7075-T6 alloy. The maximum principal stress value form analysis is used to find fatigue damage calculations for vertical tail structure. The obtained analytical result shows that safe no of fatigue life hours of vertical tail structure. The result is verified with reserve factor approach

A detailed study was carried out on crankshafts used in two wheeler made from C45 (EN 8/AISI 1042) steel. Undesirable noise was heard in crankshaft when the engine is in running. This was stated as failure of crankshaft. Material has been peeled off and seemed to be scraped at the central portion of the crankpin.  It was the bearing seating place where oil hole also provided. Under analysis the crankpin was identified as tempered. Chemical composition, micro-hardness and microstructure were studied and compared with the specified properties of the crankpin material. Reason for failure is identified as wear due to lower hardness, improper lubrication and high operating oil temperature.

Reconstruction of mandibular defects after trauma or tumor resection is one of the most challenging problems facing by reconstructive surgeons. Few mandibular defects require not just a fixation of an implant, but the reconstruction of the entire mandible. It includes deformity, trauma, infection, prior radiation exposure neoplasms, and congenital defect. The aim of this study was to design a mandibular prosthesis for a mandibular cancer patient and study its efficacy by stress–strain related mechanical property using finite element analysis (FEA). One normal young male as well as one old male diagnosed as having mandibular cancer were included in the study. In all the two cases, multi-sliced computed tomography (CT) images of mandible were obtained under standard conditions. The image was analysed by Materialise’s Interactive Medical Image Control System (MIMICS) software and ANSYS software. After applying suitable mechanical property of the bone, the biting and chewing forces were applied on the specific regions of the bone in the following cases: i) normal mandible; ii) mandible affected with cancer; and iii) reconstructed (implant) mandible. The maximum value of von Mises stress, and strain were measured; also, the vector sum of the displacement was measured. As expectedly, in mandible affected with cancer, the measured maximum values of Von Mises stress (Pa) as well as the vector sum of the displacement were increased by 50.2% and 41.1% respectively, when compared to normal mandible. On the other hand, the total strain was decreased by 71.4% in the mandible with cancer than in normal mandible. In the reconstructed mandible, the measured vector sum of the displacement and the maximum value of the strain were differed by -16.1% and -4.8% respectively, when compared to normal mandible; whereas, the measured maximum value of the von Mises stress was same in both reconstructed as well as normal mandible. Thus, it showed that, the mechanical behaviour of the reconstructed mandible was close to the same of the normal bone.