STATIC ANALYSIS OF A

BICYCLE FRAME

THIS PROJECT THESIS IS SUBMITTED PARTIALFULFILLMENT OF

REQUIREMENT FOR THE DEGREE OF B.TECH IN MECHANICAL
ENGINEERING OF WBUT

SUBMITTED BY:
ADARSH KUMAR (12000712103)
AKASHDEEP KUMAR (12000712105)
ABINASH KUMAR (12000712102)
ABHISHEK ROY (12000712100)
ABHISHEK SINGH (12000712101)
AKHILESH KUMAR (12000712106)
ADITYA RAJ (12000712104)
UNDER THE GUIDANCE OF:
MR. SUMAN KARMAKAR

DR. B. C. ROY ENGINEERING COLLEGE

JEMUA ROAD, FULJHORE

DURGAPUR 713206

Certification
This is to certify that the project entitled to Static Analysis of a
Bicycle Frame was completed by Adarsh Kumar, Akashdeep
Kumar, Abinash Kumar, Abhishek Roy, Abhishek Singh, Akhilesh
Kumar and Aditya Raj for the Bachelor of Technology in
Mechanical Engineering under my guidance and supervision. The
work fulfills the requirement for which it is being submitted.
Project Advisor
.
Prof. Suman Karmakar
Department of Mechanical engineering
Dr. B.C. Roy Engineering College, Durgapur
Counter Signed By
...
Dr. N. R. Dey
Head of Department
Mechanical Engineering
Dr. B.C. Roy Engineering College, Durgapur

Acknowledgement
We express our sincere gratitude to Prof. Suman Karmakar and
Head of Department Dr. N. R. Dey of Mechanical Engineering
Department , Dr. B. C. Roy Engineering college, Durgapur for
extending their valuable time and inspiration for taking of this
project.
We would like to thank our Guide Prof. Suman Karmakar, who has
been cooperative and motivating throughout the course of the
project. His ideas and suggestions have always been the most
appropriate and feasible.
NAME

UNIVERSITY ROLL NO.

1. ADARSH KUMAR

(12000712103)

2. AKASHDEEP KUMAR

(12000712105)

3. ABINASH KUMAR

(12000712102)

4. ABHISHEK ROY

(12000712100)

5. ABHISHEK SINGH

(12000712101)

6. AKHILESH KUMAR
7. ADITYA RAJ

(12000712106)
(12000712104)

Approval
The forgoing project is hereby approved as a work done and
presented in a manner of satisfactory to demand its acceptance
as a pre requisite to the Degree of Bachelor of Technology in
Mechanical Engineering for which it has been submitted.

Board of Examiners

Abstract

Contents

1. Introduction

..01

2. Background.....02
3. Places Visited:
3.1Steel Melting Shop......02
3.2Continuous Casting Shop...07
3.3Forge Shop. .07
3.4Blooming & Billet Mill....08
3.5Conditioning Shop...10
3.6Heat treatment & Finishing Shop...11
3.7Plate Mill......12
3.8MRS Department.....13
4. Activities of safety engineering department...14
5. Production planning & control department(PPCD)......15
6. Power Distribution......16

Finite Element Method

Introduction
The finite element method (FEM) is a powerful technique
originally developed for numerical solution of complex problems

in structural mechanics, and it remains the method of choice for

complex systems. In the FEM, the structural system is modeled by
a set of appropriate finite elements interconnected at points
called nodes. Elements may have physical properties such as
thickness, coefficient of thermal expansion, density, Young's
modulus, shear modulus and Poisson's ratio.
In practice, a finite element analysis usually consists of three
principal steps:
1. Preprocessing:
The user constructs a model of the part to be analyzed in which
the geometry is divided into a number of discrete sub regions, or
elements, connected at discrete points called nodes. Certain of
these nodes will have prescribed displacements, and others will
have prescribed loads. These models can be extremely time
consuming to prepare and commercial codes vie with one another
to have the most user-friendly graphical preprocessor to assist in
this rather tedious chore. Some of these preprocessors can
overlay a mesh on a preexisting CAD file, so that finite element
analysis can be done conveniently as part of the computerized
drafting-and-design process.
2. Analysis:
The dataset prepared by the preprocessor is used as input to the
finite element code itself, which constructs and solves a system
of linear or nonlinear algebraic equations
Kij uj = fi
where u and f are the displacements and externally applied
forces at the nodal points. The formation of the K matrix is
dependent on the type of problem being attacked, and this
module will outline the approach for truss and linear elastic stress
analyses. Commercial codes may have very large element
libraries, with elements appropriate to a wide range of problem
types. One of FEA's principal advantages is that many problem
types can be addressed with the same code, merely by specifying
the appropriate element types from the library.
3. Postprocessing:

In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing
displacements and stresses at discrete positions within the
model. It is easy to miss important trends and hot spots this way
and modern codes use graphical displays to assist in visualizing
the results. A typical postprocessor display overlays colored
contours representing stress levels on the model, showing a full
field picture similar to that of photoelastic experimental results.
NODE
A node is a coordinate location in space where the degrees of
freedom (DOFs) are defined. The DOFs for this point represent the
possible movement of this point due to the loading of the
structure. The DOFs also represent which forces and moments are
transferred from one element to the next. The results of a finite
element analysis, (deflections and stresses), are usually given at
the nodes.
The DOF of a node (which is based on the element type) also
relates what types of forces and restraints are transmitted
through the node to the element. A force (axial or shear) is
equivalent to a translation DOF. A moment is equivalent to a
rotational DOF. Thus, to transfer a moment about a certain axis,
the node must have a rotational DOF about the axis. If a node
does not have that rotational DOF, then applying a moment to the
node will have no effect on the analysis. This fact may also place
requirements on how two parts are connected together. Additional
modeling may be required to insure that the connection between
the parts does not produce a hinge. See the page "Meshing
Overview: Creating Contact Pairs: Examples of Contact" for
examples.

In
the
real
world, a

Translation
X
Y
Z

Rotation
X
Y

Element
Truss,
spring,
gap
Beam

Ye
s

Ye
s

Yes

Ye
s

Ye
s
Ye
s

Yes

2-D

Membrane
Plate, shell
Brick,
tetrahedra

Ye
s
Ye
s
Ye

Ye
s
Ye
s
Ye

Yes

Yes

Ye
s

Yes
*

Yes
*

Yes point can move in

6 different directions,
translation in X, Y, and
Z, and rotation about
X, Y, and Z. In FEA, a
node may be limited in
the calculated motions
for
a
variety
of
reasons. For example,
there is no need to
calculate the out of
plane translation on a
2-D element; it would
not be a 2-D element
if its nodes were
allowed to move out of
the plane. The DOF for
the generic element
types are given in
Table 1.
Table
1:
Degrees
of
Freedom
for
Element Types
Yes
Yes
Yes

Yes indicates the deflections are calculated. Transmission of

forces or moments is supported.
* Rotational DOF for plate elements are based on local direction
1, 2, 3 instead of global direction X, Y, Z. Rotations about the
local axes 1 and 2 (axes in the plane of the element) are
calculated. Rotation about the local axis 3 (axis perpendicular
to the element) is not calculated.
The DOF of a node (which is based on the element type) also
relates what types of forces and restraints are transmitted
through the node to the element. A force (axial or shear) is
equivalent to a translation DOF. A moment is equivalent to a
rotational DOF. Thus, to transfer a moment about a certain axis,
the node must have a rotational DOF about the axis. If a node
does not have that rotational DOF, then applying a moment to the
node will have no effect on the analysis. This fact may also place
requirements on how two parts are connected together. Additional
modeling may be required to insure that the connection between
the parts does not produce a hinge. See the page "Meshing
Overview: Creating Contact Pairs: Examples of Contact" for
examples.
Likewise, restraining that node with a rotational boundary
condition will have no effect if the node does not have the ability
to transmit the moment. So, placing a boundary condition of Tx Ty
Tz Rx Ry Rz on a node of a brick element is the same as applying
a Tx Ty Tz boundary condition; the brick element node does not
calculate the rotations.
Elements
An element is the basic building block of finite element analysis.
There are several basic types of elements. Which type of element
for finite elements analysis that is used depends on the type of
object that is to be modeled for finite element analysis and the
type of analysis that is going to be performed.
An element is a mathematical relation that defines how the
degrees of freedom of a node relate to the next. These elements
can be lines (trusses or beams), areas (2-D or 3-D plates and

membranes) or solids (bricks or tetrahedrals). It also relates how

the deflections create stresses.

Application Area of FEM:

An application of finite elements method ranges many different
fields of modern science or industry.The various applications in
the aircraft, space, shipbuilding, electrical and computer industry
as well as field of science like material engineering, mechatronics,
biochemistry and even medicine must be emphasize. Both,
technological and economical pressure in product engineering
require introduction of continuous optimization of existing
manufacturing processes, including those in designing stage. The
described method is the proper tool for these purposes.
Recently, finite element method has been arousing increasing
interest in medicine. Up to now, it is the widest applied in
modelling of: tissues (skin, bones, and muscles), implants (stents,
prostheses, elements of maxilla and teeth), and physical fields
inside the body (acoustic, electric and electromagnetic ones) and
the blood flow. For example, simulation of thigh bone with femoral
head replaced by prosthetic implant is applied mainly for the
analysis of stress, deformation and dislocation states.
FEM method of simulation gives better, more accurate and wider
results then experimental methods. Another example FEM
application is strain analysis of joints. It allows determining the
kind of stresses occurring in the bone, the location of its main
occurrence. The influence of alloplastics and osteotomy for stress
pattern in the bones can be also observed.The construction of the
rib model is the next example of FEM simulation of bones. The
analysis can be related with rib behaviour subjected to the high
force of the blow, e.g. during car accident. Finite Element Method
is also applied in creation of biostatic models of the mandible or
one-layer aortal valve.
A variety of specializations under the umbrella of the mechanical
engineering discipline (such as aeronautical, biomechanical, and

automotive industries) commonly use integrated FEM in design

and development of their products. Several modern FEM
packages include specific components such as thermal,
electromagnetic, fluid, and structural working environments. In a
structural simulation, FEM helps tremendously in producing
stiffness and strength visualizations and also in minimizing
weight, materials, and costs.
FEM allows detailed visualization of where structures bend or
twist, and indicates the distribution of stresses and
displacements. FEM software provides a wide range of simulation
options for controlling the complexity of both modeling and
analysis of a system. Similarly, the desired level of accuracy
required and associated computational time requirements can be
managed
simultaneously
to
address
most
engineering
applications. FEM allows entire designs to be constructed, refined,
and optimized before the design is manufactured.
This powerful design tool has significantly improved both the
standard of engineering designs and the methodology of the
design process in many industrial applications. The introduction of
FEM has substantially decreased the time to take products from
concept to the production line. It is primarily through improved
initial prototype designs using FEM that testing and development
have been accelerated. In summary, benefits of FEM include
increased accuracy, enhanced design and better insight into
critical design parameters, virtual prototyping, fewer hardware
prototypes, a faster and less expensive design cycle, increased
productivity, and increased revenue.
FEA has also been proposed to use in stochastic modelling for
numerically solving probability models.

Visualization of how a car deforms in an asymmetrical

crash using finite element analysis.
Advantages of FEM
1. Theoretical Advantages
Stability: Finite element methods work very well on diffusion
systems in general, and well-posedness results (essentially
stability) are very easy to establish. This is helpful to know
beforehand as it generally means that you won't have to impose
some restrictive mesh refinement before you get a nonsingular
system. (Compare to finite differences, where stability can be
difficult to establish even in the presence of a diffusive operator).
In the event that the reaction term makes this less simple,
consider a discontinuous finite element method, which includes
stabilization terms that often help.
Convergence: Convergence of a finite element method usually
is for free once you have established stability, since the
variational forms are almost always consistent with the governing
equations. Furthermore the quality of their approximation
generally follows from easily established best approximation
results.
Adaptivity: The variational framework of finite element methods

are also very amenable to a posteriori error estimation. It still isn't

easy in all cases, but there are some highly generalized
approaches which almost always give at least a useful estimator
which can be used to tell you where to refine your mesh (and
where not to). This is very difficult to accomplish in a finite
difference method, where you generally have to rely on indicators
instead of estimators.
2. Computational Advantage
Hybridization: Writing the second order term as a system of two
first order terms (the so-called mixed formulation), and then
explicitly including coupling terms in your formulation permits a
nice technique known as "static condensation," and the overall
process of doing this is called "hybridization." This lets you solve
a much smaller system for some degrees of freedom, and then
solving all of them is usually a cheap second step. Coupling in
finite differences is not generally amenable to this type of
manipulation.
hp-versions: Finite element methods very naturally allow the
use of variable approximation order in each element. The higher
your approximation order the more optimal your method is (but is
only applicable in regions where the solution has higher
regularity). Still, if you have some foreknowledge of the solution's
regularity, this can dramatically improve your runtime and
memory usage. In the best case scenario you can achieve
"exponential," or "spectral" convergence, which is essentially the
fastest possible convergence you can obtain. This is hard to do in
a local way with finite difference methods, they often come in a
one-size-fits-all approximation order that can not be changed
except
for
changing
the
entire
scheme.
3. Flexibility Advantages
Inhomogeneity: Finite element methods more naturally account
for inhomogeneity in problems, where including them in your
formulation generally just means you have to use higher order
quadrature rules, and then stability still follows provided you use

the "right" quadrature (problem dependent). Finite difference

methods typically have to use complicated interface conditions to
accomplish the same thing, but in finite elements it's free.
Complex geometries: Provided you have a good mesh
generator, you can theoretically solve your system on just about
any geometry in finite element methods with zero change to your
code.
Boundary conditions: These can be very easily imposed in a
finite element method, and you could even resort to using "weak
boundary conditions" if it's not obvious how to do it "strongly".

Disadvantages of FEM
We need the computer programs and other facilities for the finite
element method analysis.
It does not give accurate results. All the results are approximate.
FEM gives solution only at nodal point.
A general closed-form solution, which would permit one to
examine system response to changes in various parameters, is
not produced.
The FEM has "inherent" errors. Mistakes by user can be fatal.s
The disadvantage is the models are time-consuming to create,
and verify, can be sensitive to boundary conditions (stress
concentrations, local stresses) and sometimes the model needs to
be refined repeatedly to give assurance that the results are
reasonably accurate/valid.
In spite of the great power of FEA, the disadvantages of computer
solutions must be kept in mind when using this and similar
methods: they do not necessarily reveal how the stresses are
influenced by important problem variables such as materials
properties and geometrical features, and errors in input data can

produce wildly incorrect results that may be overlooked by the

analyst.

ANSYS
INTRODUCTION
ANSYS is a general purpose finite element simulation package for
numerical solving a wide variety of design engineering problems.
These problems include: static/dynamic structural analysis (both
linear and non-linear), heat transfer and fluid problems, as well as
acoustic and electromagnetic problems. There is possibility of
solving mixed problems connecting the ones described above.
The product includes many special tools that help in analyzing
such effects as: plasticity, large deformations, hiperplasticity,
creep, high deflection, interface contact, dependence of various
properties on temperature and pressure, anisotropy and radiance.
For example, the possibility of substructures, submodelling and
optimization are available. The ANSYS has been already used for
commercial purposes since 1970. A variety of specializations
under the umbrella of the mechanical engineering discipline (such
as aeronautical, biomechanical, and automotive industries)
commonly use ANSYS software package in design and
development of their products. It is also used in electronic and
power engineering, including nuclear power engineering, oil and
steel industry as well as in material engineering.
The finite element analysis package ANSYS enables engineers:
Construction of geometrical model or reproduction of
existing models already made in other commonly used CAD
programmes.
Introduction of exploitation loads or other conditions
connected with the work of analyzed system.
Analysis of stresses, temperature distribution, etc.
Designed system optimization at the pre-calculation stage.

 Making of such simulations of working system that are

impossible to do in any other way (e.g. in biomechanical
application).
ANSYS Workbench is most chosen package because of its
easiness to use and intuitive user interface, allowing quick and
simple program operation. The ANSYS Workbench hosts many
software products and components enabling for the optimal
selection of options required for ones own purposes and the
optimal design of the construction ( e.g. with the minimal weight,
suitable shape), in this way the total number of expensive
prototypes is reduced as well as the time of the introduction of
final product to the market. With unusual CAD connectivity, an
automated project update mechanism, pervasive parameter
management and integrated optimization tools, the ANSYS
Workbench platform delivers productivity that truly enables
product development through simulation.
Some of the examples of the various and numerous ANSYS
Workbench applications are listed below:
Mechanical - applied for structural linear/nonlinear and
dynamics analysis, it offers a complete set of elements
behaviour, material models and equation solvers for a wide
range of engineering problems including thermal analysis
and
coupled-physics
capabilities
involving
acoustic,
piezoelectric,
thermal-structural
and
thermal-electric
analysis.
Mechanical APDL - dedicated for advanced mechanical and
multidisciplinary analysis using traditional, classic users
interface of ANSYS.
Fluid Flow (CFX) - a high-performance, general purpose CFD
that enables capturing virtually any type of phenomena
related to fluid flow.
Fluid Flow (FLUENT) - software contains the broad physical
modeling capabilities needed to model flow, turbulence,
heat transfer, and reactions for any industrial applications.
Geometry (Design Modeler) - the feature-based, parametric
software that can be used to create parametric geometry

from scratch or to prepare an existing CAD geometry for

further analysis.
Engineering Data - a module applied for import/export
material data as XML files.
Meshing Application - applied for CFE mesh creation and
Explicite Dynamice, the product allows the user to find the
balance and get the right mesh for their simulation.
Finite Element Modeler (FE Modeler) - applied for the
conversion of FEM mesh between NASTRAN ABAQUS and
ANSYS programmes.
BladeGen (Blade Geometry) - a specialized, easy-to-use tool
for the rapid 3-D design of rotating machinery components.
Explicite Dynamice - an advanced explicit analysis tool for
modelling complex nonlinear dynamics.
The software offers very wide spectrum analyses ranging from
statistics to electromagnetic field via phenomena variable in time
and possibility of linear/nonlinear phenomena analyses. Complete
analysis systems are convenient because they contain all of the
necessary tasks or components to complete start-to-finish
simulations starting from definition of problem, through
calculation of the problem up to verification of derived results
without necessity of using additional external software. Therefore,
there are many prerequisites for successful applying ANSYS
Workbench in material engineering as well as in many other
disciplines of science and industry.

Application Area of ANSYS:

During the late seventies, a large number of simulations in the
design process of nuclear power plants were performed using
ANSYS. Most of the load cases were transient and temperaturedependent, including varied pressure cycles. A number of
geometries were represented by axisymmetric two-dimensional
models, e.g. structures such as nozzles /23/. Also, threedimensional transient calculations were performed with a very
large amount of computer resources. Several batch jobs that took
a couple of weeks to obtain the final results of the analysis

existed. In the case of linear static analysis for complex structural

components without transient effects, shell or volume models
with an increased number of elements were created.
Before detailed analysis became commonplace, beam element
models were used to study the behavior of complex structural
components. The main benefit was to receive a very quick answer
regarding the global stress distribution. The most tedious and
time-consuming work of those models was to calculate the
moments of inertia and find the right orientation, due to poor
capability of plots showing the element coordinate systems.
Furthermore, post-processing of the results was complicated
because no graphic algorithms were available for beam elements
to show the stresses.
With the continued development of computer hardware, shell
elements were used to model thin structures in combination with
beam elements to simulate the boundary conditions. To solve
models with large numbers of elements, the so called
substructure technique was used. It was possible
to subdivide structures into discrete parts represented only by a
stiffness matrix generated from a separate finite element model.
Using this procedure, the parts of the structures were combined
numerically to form the complete component. A number of
calculations had to be made before the results could be shown .

Defining a geometry using ANSYS Rev. 2 in the

design process
The first case described is the analysis of a square support beam
using Rev. 2 of ANSYS /4, 7/. It is interesting for todays users to
learn how geometry was defined for Rev. 2 without the help of
any geometry modeling capabilities or possibilities to read CAD
data. No graphics exist for the
original analysis, but the geometry shown in Figure 1 is similar to
that which is described here.

FIGURE 1
The first task was to discretize the structure into nodes and
elements. For this discretization process, the experience of the
user was needed. First, to devise a finite element model that
would yield an acceptable stress distribution (reasonable element
shapes and sizes). Second, to optimize the wave front (number of
active equations in the solution process), to allow the model to be
solved in the available memory of the computer in a reasonable
period of time.
To create the finite element model, the user would separate the
geometry into four flat panels and then generate a pattern of
nodes to produce quadrilateral shell elements on each panel. The
number of nodes on each edge could not be too high, in order to
minimize the wave front. The frontal method equation solver has
to build up the element matrices from the node and element
numbers. In order to minimize the wave front, the numerical
difference of the node numbers defining an element needed to be
kept as small as possible.
For demonstration purposes, only the simple model was meshed
(Fig. 2). It can be seen that the sorting of the elements is
important for the wave front. The element connectivity should be
started along the shortest edge of the structure in the direction of
the arrow. The advantage of the frontal equation solver is that

solution times and memory requirements are independent of the

largest node number (unlike other methods).

FIGURE 2
The next problem to overcome was the assembly of the finite
element meshes on each side panel. To achieve this, the nodes on
each mating edge of the panels needed to have the same
numbers and the same spatial definitions to enable assembly. A
command to merge coincident nodes like
nummrg,node was not available in Rev. 2.
A further consideration during the model development was to
minimize the amount of data to be entered using the generation
capabilities available in the program. Data entry was a laborious
task and could take hours of manual typing on a computer key
cardpunch or computer terminal. ANSYS allowed nodes to be
generated using a geometric increment or filling node numbers
between the existing ones. Using a node number increment, a
given pattern of elements could be generated. At the time, a lot
of users wrote their own small FORTRAN programs to generate
the input data sets for special classes of geometry.
One additional item should be mentioned to review the use of
ANSYS in the past, which was the issue of graphical output. It is
very tedious to perform a finite element calculation without
graphics. After using the drum plotter located in the data center

for many years, the first graphical screen was delivered. The time
to get a plot was then reduced by a factor of 5 to 10. There were
no interactive graphics like todays programs. A hardware
dependent plot file was written using software libraries provided
by the hardware vendor. This was one of the major changes of
graphic systems using finite element software.
This short review of the difficulties in the past is intended to show
the development of the enhanced capabilities of the ANSYS
program. Today, this simple model can be defined and meshed
within a few minutes.

Advantages of ANSYS

TRUSS

In engineering, a truss is a structure that consists of two-force

members only, where the members are organized so that the
assemblage as a whole behaves as a single object.
A "two-force member" is a structural component where force is
applied to only two points. Although this rigorous definition allows
the members to have any shape connected in any stable
configuration, trusses typically comprise five or more triangular
units constructed with straight members whose ends are
connected at joints referred to as nodes.
In this typical context, external forces and reactions to those
forces are considered to act only at the nodes and result in forces
in the members which are either tensile or compressive. For
straight members, moments (torques) are explicitly excluded
because, and only because, all the joints in a truss are treated as
revolutes, as is necessary for the links to be two-force members.

Thus truss is a structure that consists of:

All straight members
Connected together with pin joints
Connected only at the ends of the members
All external forces (loads & reactions) must be applied only
at the joints.

FRAME
Frames are structures with at least one multi-force member, i.e.
at least one member that has 3 or more forces acting on it at
different points.