INTRODUCTION:

Project Title : DESIGN AND LOAD ANALYSIS OF STORAGE BINS USING

CREO 2.0 AND CATIA V5 R18 SOFTWARE.
Duration of Project: AUGUST 2013 TO NOVEMBER 2013.
Organization : SANJANA METALWARE INDIA (P) LTD, INDIA.
Position : Independent
Location : SANJANA METALWARE INDIA (P) LTD
21-H, Industrial Estate
Ambattur, Chennai - 600 098, India
OVERVIEW:
A project titled “Design and load analysis of storage bins using CREO 2.0 and CATIA
V5 R18 software”. This project was carried out in order to fulfill my requirement for
the organization. In this project a sheet metal component was designed and load
analysis was carried out using CATIA V5 R18. The component selected for this
project was sheet metal storage bins. The steps carried out in designing and load
analyses of component are explained in detail in this report. The project consisted of
the following steps: Design and modeling of the storage bins using CREO 2.0 and
analysis of the model in CATIA V5 R18. The sole reason for the selection of this
project was my passion towards designing. The main objective of this project was to
design a sheet metal component and also analyze load capacity of the component
so that a good can be designed to facilitate mass production. This project on
completion helped me to be more proficient in the use of CERO 2.0 and CATIA V5
R18 Software.

BACKGROUND
The Computed aided design and manufacturing are one of the most important
concepts in the modern world. Design using the 3D modeling software gives you full
3D preview of the model digitally. These models can be assembles and subjected to
various analyses and respective theoretically result can be obtained. These results
form guidelines for the design and manufacturing department. From these data the
designers or manufactures can redesign or rework on the component for better
efficiency and better aesthetics. In this project the component was primarily designed
in CREO 2.0 and then the model was exported to IGES format. The iges file was
then imported to CATIA V5 for further analysis. Thus helps us to determine the ideal
combination of part geometry, material, and load conditions that produces quality
storage bins by sheetmetal process.

ORGANIZATIONAL STRUCTURE

COURSE OF ACTION:
In this project a sheetmetal component was designed and static and thermal analysis
using CATIA V5. The component selected for this project was a Storage metal bin.
The steps carried out in designing and analysis component are explained in this
report. This report consists of the following steps explained individually.

 Design and modelling of the part on the CREO 2.0.

 Importing the model into CATIA.
 Assigning material for the component.
 Meshing the model with custom element size.
 Analysis of the component
 Results.

PERSONAL ENGINEERING ACTIVITY

The projected had ample of time as this was the only project that was that was
carried out during the whole semester. There was also plenty of work that had to be
carried out to support the project to perfection. The new component was selected as
part of the project. The component was designed using 3D modeling software CREO
2.0. A report was generated with data’s from the 3D model and Design data book.
The report contains the essential information that is required for manufacturing the
model. The project was completed within a short period of time due to my hands on
experience in CERO 2.0. The created model’s diagrammatical representations are
as follows.
 Figure 1 - Bucket in the Initial stage

TOPIC
The initial process of the design was to extract the design parameters from the
component. Then the designing process started with the available data’s and few
assumptions were made for the model as some dimensions were unavailable. The
assumptions were also required so that future analysis can be performed. The main
modeling was carried out in the CREO 2.0 Software using the tools like extrude and
revolve and revolve cut and flange. The model was created from the extracted
dimensions and smaller changes were made to the model to make it better in
regards of aesthetics, strength and durability. A hopper was made with an angle 5
degrees with reference to the data book the angle of the hopper should be no more
that 00 – 200 (α < 20). The 3D model was created with a material thickness 1.5 mm.
There were small protrusion provide in the walls of the storage bin to make increase
the strength and to improve the look. The model was again selected to perform the
small protrusion cut in the bottom. Thus the bucket model was designed using the
CREO 2.0 software. Figure 2 gives us a diagrammatical view of the finished model.
 Figure 2 - Bucket model with the rings

The edges of the models were bent using the flange option available in the CREO
2.0. This is done to blunt the sharp edges in the model so that it will be safer while
handling. The figure 3 shows the final model after adding the flange.

Figure 3 - Fully furnished model

TOPIC
The appearance of the componenet is changed by using the “Appearance galary”
in the Rendereing option. The colour are the material application are controlled in
the rendereing region. This makes the model more relastic. colour of the component
is changed this is done by selecting appearance option from the view editor and the
colour is changed to suit our requirement. The fully rendered component which is
shown in figure 4. The Analysis can either be carried out in the CREO 2.0 or can be
exported to other software for further analysis.

Figure 4 - Finished component Figure 5 – Manufactured component

ANALYSIS:
The completed model is the subjected to load in the Computer Aided Three
Dimensional Interactive Application CATIA V5 R18 software.

Figure 6 -Imported model (from .IGES file)

The exported IGES file from the CREO 2.0 software. The .Iges file was opened in
the CATIA V5 R 18 software for further analysis. The Iges file creates solid file same
as the designed model in CREO 2.0. The material was assigned to the model in
CATIA for the analysis. The material selected for the component was Stainless Steel
material grade 304 / 304L. The storage bin was made in the thickness of 1.5 mm as
the size of the component was 30x60. The stainless steel material 304 / 304L were
used because of their mechanical and physical properties. The material properties
are as follows.

MECHANICAL PROPERTIES:

Figure 7 Mechanical Properties (with reference to AK Steel Ohio)

PHYSICAL PROPERTIES:
Density
 0.29 lbs/in3 - 8.03 g/cm3
Electrical Resistivity, microhm-in (microhm-cm)
 68°F (20°C) – 28.4 (72)
 1200°F (659°C) – 45.8 (116)
Specific Heat, BTU/lb/°F (kJ/kg•K)
 32 - 212°F (0 - 100°C) – 0.12 (0.50)
Thermal Conductivity, BTU/hr/ft2/ft/°F (W/m•K)
 at 212°F (100°C) – 9.4 (16.2)
 at 932°F (500°C) – 12.4 (21.4)
Mean Coefficient of Thermal Expansion,in/in/°F (μm/m•K)
 32- 212°F (0 - 100°C) – 9.4 x 10-6(16.9)
 32- 600°F (0 - 315°C) – 9.6 x 10-6(17.3)
 32-1000°F (0 - 538°C) –10.2 x 10-6 (18.4)
 32-1200°F (0 - 649°C) –10.4 x 10-6 (18.7)
Magnetic Permeability, H = 200
Modulus of Elasticity, ksi (MPa) –
 28.0 x 103 (193 x 103) in tension
 11.2 x 103 (78 x 103) in torsion
Melting Range, °F (°C) – 2550 – 2650 (1399 - 1454)

The storage bin was meshed with a tetrahedron element of size 4mm. The accuracy
of the result was increased with the decrease in the element size. The designing of
the storage bin took more time usual as the it requires more data’s from data books
and research for the of the material. These steels exhibit excellent resistance when
exposed to chemical, textile, petroleum and food based industries. After assigning of
the material the loading on the storage bin was done. An internal pressure of 50
N/m2 was applied to the inner walls of the storage bin. The DOF for the base of the
storage bin was arrested in X, Y, Z direction. The following diagrams show the
application of the loads.

Figure 8 loading of the model

After the loading and meshing the model was computed completed with all the
standards.
 Figure 9 - Load application and solving

RESULTS:

The principal stress and displacement were obtained from the analysis. The main
objective was to find the permissible limit of the storage bin. The deformation was
minimal for the applied load. As the analysis conclude that the redesign was success

PRINCIPLE STRESS:

Figure 10 - Principal stress

DISPLACEMENT:

Figure 11 Displacement

PRESENTATION AND DOCUMENTATION:

The designing process required reference from books, journals and video tutorial,
online articles. For the material and other essential data’s required for the designing
were collected from the real time model and similar existing models. The report gives
detailed information regarding the design process that was carried out by me and
also the loading and analysis. There project had few problems encountered during
the designing process but they were all solved either by redesign or by using
alternate method. In the end a full report was submitted to my project guide and a
presentation was given in the class about my project. I also clarified the doubts
raised by my classmates about my project.
SUMMARY:
This was the first project done by me involving CREO 2.0 and CATIA V5 R18. This
project helped me to learn more about how these two software’s are being used by
many manufacturing companies. And with an encouraging feedback which I got for
my project from the guide has improved my confidence better in handling projects
individually and working in the same area of study.