INTERNSHIP REPORT

ON
STRUCTURAL ANALYSIS OF AIRCRAFT BRACKET AND
PRESSURE VALVE USING ANSYS

A report thesis for the partial fulfilment of the requirement for the award of degree

BACHELOR OF ENGINEERING
IN
MECHNAICAL ENGINEERING

Submitted by

MOHAMMED ZIA AHMED KHAN

1604-17-736-070

Under the guidance of

AHMED ABDUL MUNEEM

ASSOCIATE PROFESSOR

DEPARTMENT OF MECHANIICAL ENGINEERING

MUFFAKHAM JAH COLLEGE OF ENGINEERING AND TECHNOLOGY
(Affiliated to OSMANIA UNIVERSITY, Hyderabad)
Banjara Hills, Hyderabad
 CERTIFICATE
This is to certify that the internship report entitled “Structural Analysis of Aircraft Bracket
and Pressure Valve using ANSYS” is the work done by Mr. Mohammed Zia Ahmed Khan,
Hall ticket number 1604-17-736-070 during the academic year 2020 – 2021, for the partial
fulfilment of the award Degree of the Bachelor of Engineering in Mechanical Engineering.

Dr. Mohammed Viqaur Mohinuddin Mr. Ahmed Abdul Muneem

Professor and Head, Internship Coordinator,
Dept. of MED, Associate Professor, Dept. of MED,
MJCET, Hyderabad MJCET, Hyderabad
 PREFACE

This project report is prepared during the summer industrial training undertaken at
“ENTUPLE TECHNOLOGIES” as partial fulfilment of the degree in “B.E Mechanical
Engineering” at Muffakham Jah College of Engineering and Technology, Hyderabad.
Theory of project is important, but without practical knowledge, it becomes futile particularly
for the engineering students. The knowledge of engineering is incomplete without the
practical applications of the theories studied. This training provides an excellent opportunity
to all the students, especially engineering students to get to know properly how the Ansys
Workbench software works and how to perform meshing in it. Hence, this report has been
designed with the objectives to gain knowledge about what was taught and what projects
were given at the end of the online internship.

Acknowledgement
Online training at ENTUPLE TECHNOLOGIES had been a great learning experience for
me. The theoretical knowledge I gained during years of study at MJCET, Hyderabad had
been effectively complemented due to the guidance and support provided by ENTUPLE
employees. The factors that are to be considered while meshing any component cannot be
fully covered theoretically. This practical knowledge could have only be guided by handling
few case studies and performing various experiments using the software.

I would like to acknowledge Mr. Gokul, company guide, for allowing me to complete my
training at ENTUPLE under knowledgeable training guides who were happy to pass on their
wisdom guided over experience. The process of teaching and giving practical experience
soon after, was an effective one.

Finally, I would like to thank Head of Department Dr. Mohammed Viquar Mohinuddin for his
support throughout my internship

I would like to thank Ahmed Abdul Muneem, College internship guide and K.Sasidhar Sir
Department internship coordinator for their support and advices to get and complete
internship in above said organisation

Mohammed Zia Ahmed Khan

(1604-17-736-070)
 WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES
Date Day Topic
1EKWE
June 10 Wednesday Introduction to SpaceClaim
June 11 Thursday Ansys Workbench
June 12 Friday Ansys Meshing
June 13 Saturday -------------------
June 15 Monday Static Structural Analysis
June 16 Tuesday -------------------

Date Day Topic

2EKWE

June 17 Wednesday Introduction to Thermal FEA

June 18 Thursday -------------------
June 19 Friday Basics of Non-linear Analysis
June 20 Saturday -------------------
June 22 Monday Basics of Contact Analysis
June 23 Tuesday -------------------

Date Day Topic

3EKWE

June 24 Wednesday Introduction to Optimization

June 25 Thursday -------------------
June 26 Friday Example demonstration
June 27 Saturday Projects Assigned
June 29 Monday -------------------
June 30 Tuesday -------------------

Date Day Project Weeks

54&EKWE

July 1 Wednesday
July 2 Thursday
July 3 Friday
July 4 Saturday
July 6 Monday
July 7 Tuesday
ANSYS MESHING:
Meshing is an integral part of the engineering simulation process where complex
geometries are divided into simple elements that can be used as discrete local
approximations of the larger domain. The mesh influences the accuracy, convergence and
speed of the simulation.

LINEAR STATIC STRUCTURAL ANAYSIS:

A linear analysis is conducted if a structure is expected to exhibit linear behavior. The
deformation and load-carrying capability can be determined by employing one of the
analysis types available in ANSYS, static or dynamic, depending on the nature of the applied
loading.

BASIC NON-LINEAR ANALYSIS:

A nonlinear analysis is an analysis where a nonlinear relation holds between applied forces
and displacements. This is opposed to the linear static analysis, where the stiffness matrix
remained constant. As a result, a different solving strategy is required for the nonlinear
analysis and therefore a different solver.

FEA OPTIMIZATION:
Design optimization is one of the largest advantages of finite element analysis (FEA). Though
gaining a strong understanding of the performance of your product with FEA you can reduce
material, prevent stress concentrations, remove bottlenecks, and attain desirable
performance attributes. All the above topics were taught to us with the help of an example
that was solved in Ansys Workbench and then gave a detailed explanation about the results
and future applications and its uses. After covering all the topics starting from theory to
practically explaining using the software , we were then given a project at the end of the
internship

Project Work
1) Structural Analysis of an Aircraft:
Objective:

 To perform structural analysis of aircraft bracket and need to identify the hot
spots(region more prone to failure upon increase in load)
Parts & Materials for Analysis:

 Part : Aircraft Bracket

 Material : Aluminium 7075-T6
Analysis Assumptions:

 Lightweight Aluminum alloy 7075-T6 Material is considered in this analysis

 Analysis performed is qualitative.
 To find Stress points considering yield safety factor as 2, application of force of upto
2500N is assumed to be gradual and along Z-direction.
 Force is equally distributed in 10 load steps across 10 second time period with linear
increment.
 Cylindrical faces of bolt holes are constrained in all directions.

Boundary Conditions:
 Loads and fixtures
Equivalent stress points:

The stresses produced in the bracket are 263.03 Mpa of Maximum and 0.070798 Mpa of
Minimum because of the boundary and load conditions.

Equivalent stress Plot:

Force is loaded incrementally in 10 load steps across 10-second period.

Results and Discussion:
 The results we obtained by performing non linear FEA of the Bracket may not be up to
the mark but they are logically correct as the bracket is subjected to tensile force of 100
N.
 The stresses produced along the -Z axes in the bracket are due to the tensile force acting
on the inner surface of the hole in bracket.
 If the tensile yield strength of the material is less then the deformation and stresses will
be increased compared to this.
 For the same boundary conditions, stress and strain depends on the Young’s Modulus
and Ultimate Yield Strength
 As the material used is Aluminium Alloy, we are getting more deflection and stresses, if
we have used Structural Steel or stainless steel we get less deflection, at cost of weight.

Conclusion:
 From the simulation we performed using Ansys , we can predict the failure of the aircraft
bracket and the maximum stress and strain that will be produced.
 With the information we obtained from the results of the simulation and analysis we can
make certain changes in either the geometry or in the material properties to have an
efficient aircraft bracket.
 Meshing performed in the analysis is to analyse the component at element level which
helps to determine the capacity or the failure points of the component.
 By simulating and analysing the component under different conditions and loads, we can
save a lot of money and work as we can have a particular idea or clarity of approach.
2) Non-Linear Finite Element Analysis of Pressure Valve :

Objective:

 To perform the nonlinear Finite Element Analysis of pressure valve subjected to an

internal pressure and a tensile force.

Parts & Materials for Analysis:

 Part 1: male threaded part

 Part 2: Female threaded part
 Structural steel material ( E = 3e6 MPa)

Analysis Assumptions:

 The young’s modulus of material :- 3e6 Mpa

 The poission’s ratio :- 0.3
 Yield strength :- 750 Mpa
 Tensile Yield strength :- 9000 Mpa
 Tangent Modulus :- 3e5 Mpa
 Type of contact between the bodies :- Frictional Contact
 Frictional Coefficient :- 0.1
 Meshing Method :- Tetrahedron
Boundary Conditions:

 Fixed support is applied at the bottom face. [A]

 Force of 6000N is applied on top surface. [B]
 Pressure of 4 GPa is applied on inner surface [C]

 Contacts are as shown:

Equivalent stress Plot :

Force and pressure are loaded incrementally in 10 load steps across 1-second period.

Final Stress Distribution:

Total Deformation Plot :

 Deformation trend across 10 load steps across 1-second period.

Total Deformation :

Equivalent Plastic Strain Plot:

Final Equivalent Plastic Strain:

Results & Discussion :

 Results seem to be acceptable considering the loading, boundary, and contact conditions
employed during this analysis.
 According to design limitations, max allowable deformation in valve is 0.9m. (Difference b/n
thread radii)
 From Above evaluated results, corresponding to plastic strain plot (time stamp = 0.35 sec), it is
suggested to keep operational internal pressure and tensile force below 1.47e+09 Pa and 2225N
at all times to avoid any plastic deformation and for longer product life.
 This FEA does not determine Complete failure of product.
 Higher pressure requirements will necessitate better material properties.

Conclusion:

 From the simulation we performed using Ansys , we can predict the failure of the pressure valve
and the maximum stress and strain that will be produced.
 With the information we obtained from the results of the simulation and analysis we can make
certain changes in either the geometry or in the material properties to design an efficient
pressure valve.
 Meshing performed in the analysis is to analyse the component at element level which helps to
determine the capacity or the failure points of the component.
 By simulating and analysing the component under different conditions and loads, we can save a
lot of money and work as we can have a particular idea or clarity of approach.