Professional Documents
Culture Documents
SEMESTER 2
SESSION 2020/2021
COURSE CODE: EPF4702-1: (FABRICATED FOOD TECHNOLOGY)
GROUP: 2
INTRODUCTION......................................................................................................................2
CONCLUSION........................................................................................................................19
REFERENCES.........................................................................................................................20
List of Tables
List of Figure
1
INTRODUCTION
Curry puff is a dough filled with chunks of potatoes and sometimes small pieces of
chicken and chopped boiled egg which is cooked in the spicy and flavorful Malaysia curry,
then deep-fried. This classic Malaysian pastry is well known throughout the country and
getting more popular across the world. Here, the prices of curry puffs are relatively cheap,
around RM 0.40 each.
Traditionally, making curry puff is simply by filling some potatoes in the center of a
thin round piece of dough about 10 cm wide. Then, fold the pastry in half and seal the edges
by pressing and folding them with our fingers. After being deeply fried, the curry puff was
ready to eat.
In 2016, Prof. Dr. Rosnah Shamsudin from the Faculty of Engineering has invented a
Curry Puff Maker which allow 12 puffs to be formed at a time. This process starts by
manually laying the dough sheets and fillings, then hand-swing the handle that is
incorporated as part of the machine. The invention works on the mechanism of the
connecting rods that relay the next fold clamp sets. The machine can carry out multiple
functions simultaneously such as folding, pressing, cutting, designing, and eliminating excess
dough. The dimension of the machine is 560 mm(L) x 720mm(W) x 230mm(H).
The Curry Puff Maker will help businesses owners to mass-produce their product thus
increasing their profit. The machine has finished its design and prototype stages, yet it still
requires several testing and verification before ready to be commercialized. Comprehensive
testing of the final product takes place to evaluate the robustness of the design and its ability
to meet customer and performance requirements.
Objectives:
Besides that, the stress, strain, and deformation of a chosen component or critical area
will be investigated under a range of load conditions to verify the structure’s strength for its
uses. Lastly, under the same exerted load and condition, a different type of material was used
as an alternative to understand structural behavior and therefore remove uncertainty in the
design phase.
2
MATERIALS AND METHODS
Selection of the
Comparison
Material Finite element most suitable
with another
selection analysis material for the
material
critical part
3
the component. The stress analysis is performed using a linear elastic isotropic model, and the
maximum von Mises stress is used in this study to determine a default failure.
Critical point
Critical
component
chosen
Figure 3: The component chosen as a critical part in curry puff machine (4MM-SUS-2PCS-
K87-PART-9)
1. Material selection
The material used for the critical component is stainless steel 316. Stainless
steel refers to a type of steel defined by chromium and other alloying elements, such
as strong and highly durable (Ltd., 2021). Compared to stainless steel 304, stainless
steel 316 is more suitable for commercial kitchen surfaces, equipment, and
appliances.
Besides, carbon steel is far lower in chromium and is a carbon-iron alloy with
barely, if any, a few other components. Therefore, instead of stainless steel 316, plain
carbon steel would be an alternative material for the critical component as it is less
expensive than stainless steel and wear-resistant (Ltd., 2021).
6061 aluminium alloy is also one of the most common and most versatile
extrusion alloys. It is commonly referred to as structural aluminium because it is ideal
for structural applications with its strength. The difference between aluminium 6061
T6 and T4 is T4 naturally aged while T6 temper aluminium is artificially aged for
maximum strength (6061 Aluminum: Get to Know Its Properties and Uses - Gabrian,
n.d.). Aluminium alloy 6061 is a treatable heat alloy with a strength greater than
6005A with medium to high strength. Its high resistance to corrosion and excellent
weldability, although the welding area is less strong (Aluminium Alloy - Commercial
4
Alloy - 6061 - T6 Extrusions, n.d.). Hence, aluminium 6061-T6 would be a good
competitor for stainless steel 316 and plain carbon steel.
The properties of stainless steel 316, plain carbon steel and aluminium 6061-
T6 are shown in Table 1 below.
5
Fixture/ boundary condition:
2. Force
In addition, the force applied at the area connecting with the handle upholds
the weight of the hairlines and moulds. Thus, the force is set at the edge of the hole
connected to the handle. The areas circled in red (refer to Figure 5) indicated the area
in which the high force will be imposed. For this study, two loads will be evaluated,
which are 3.646 kg and 30 kg.
6
Hairlines
Mould
The usual load that will be applied to the curry puff machine is 3.646 kg. The load is
due to the mould mass, 13.8 grams, and the hairline mass, 1146.43 grams. The total number
of moulds and hairlines that the component needs to bear are 15 moulds (black arrow, refer to
Figure 6) and three hairlines (yellow arrow, refer to Figure 6).
Hence, 3646.29 g is the total weight of 15 moulds and hairlines. However, the
component chosen applied in pairs. In this study, only one side of the component is
evaluated. Hence, 18.23 N is the force applied to the hinge (critical component chosen)
during simulation.
To produce a robust feature that can withstand heavy loads, a higher load of 30 kg is
evaluated. A figure for unprecedented events such as the severe human impact on the
machine (fall or bump) and loads stacking on top of the machine should be considered.
However, the component chosen applied in pairs. In this study, only one side of the
component is evaluated. Thus, 150 N is expected to be applied to the hinge (critical
component chosen) during simulation.
7
Table 2: Loads information generated from SOLIDWORKS
3. Meshing
Based on Table 3, shell mesh is used with an element size of 1.72035 mm and a
tolerance of 0.0860174 mm to achieve a high meshing quality (fine). The aspect ratio control
is used by the program automatically to monitor mesh quality. In solid mesh, there are
particular quantities about the aspect ratio to evaluate a good meshing. However, there is no
aspect ratio information of the component. The component used Shell Mesh Using Mid-
surfaces as mesh type rather than solid mesh due to the thin models of the component chosen.
Solid mesh can be applied to a solid model with tetrahedral solid elements (Systèmes.,
2018b).
8
In geometry, tetrahedral is a polyhedral angle with four faces. However, the
component chosen is a thin plate. Meshing thin models with solid elements results in
generating many elements that deteriorate the quality of the mesh and leads to inaccurate
results (Systèmes., 2018c). Hence, the meshing applied in (Figure 7) used shell mesh using
mid-surfaces. Systèmes (2018b) explained that the aspect ratios of other elements are
calculated using the aspect ratio of a perfect tetrahedral element as a starting point. The
aspect proportion of an element is defined as a ratio from the vertex to the opposite face,
normalized concerning a perfect tetrahedral, between the longest and the smallest normal.
The aspect proportion of an element is defined as a ratio from the vertex to the opposite face,
normalized concerning a perfect tetrahedral, between the longest and the smallest normal.
9
RESULTS AND DISCUSSIONS
Table 4: Table of von Mises stress for different materials and loads
150 N
Load (N)
18 N
0.00E+001.00E+072.00E+073.00E+074.00E+075.00E+076.00E+077.00E+078.00E+079.00E+07
Von Mises Stress (N/m2)
material to observe the effect on the critical part, which is the hinge. The hinge (Figure 9)
which connects the handle and is used to lift up the hairlines and mould. The activity of
clamping the mould repeatedly may result in damage to that part. Based on the result above,
with a load of 18.23 N, AISI 316 stainless steel has higher tolerance of Von Mises Stress with
minimum value of 1.126 x 104 N/m2 to a maximum of 9.620 x 106 N/m2 compared to plain
carbon steel. Still, AISI 316 Stainless steel and plain carbon steel only have slight differences
in the maximum von Mises stress when being imposed with 18.23 N load. Von Mises Stress
is defined as the value determining the yield level of a ductile material under any loading
10
force before the distortional energy reaches its yielding point. For the yield strength, plain
carbon steel and AISI 316 stainless steel have 2.206 x 10 8 N/m2 and 1.724 x 108 N/m2
respectively. Yield strength is defined as the stress point at which the permanent deformation
will occur. When the material is imposed by a stress lower than the material yields stress, it
will undergo elastic strain and result in no permanent deformation on the material. As plain
carbon steel has lower maximum value of Von Mises Stress compared to AISI 316 stainless
steel, this indicates that plain carbon steel has higher range before the critical part undergoes
permanent deformation after being forced with 18.23 N load. In short, plain carbon steel can
resist more stress before changing shape compared to AISI 316 stainless steel. Despite that,
when comparing based on different loads, the load with 18.23 N has maximum von Mises
stress, 9.617x 106 N/m2 while with 150 N load, the maximum limit is 7.913 x 10 7 N/m2.
Comparing the colour intensity especially at the screw part, the intensity and diameter of the
green colour is greater for 150 N (Figure 10) compared to the green intensity for 18.23 N
(Figure 9). Also, a little bit of orange colour can be spotted inside the green colour parts.
Here, load of 150 N is considered to observe the strength of the material and effect on the
machine’s part when being imposed to excessive load. During the machine operation, this
screw part is indeed the most critical part and the greater the load will lead to higher damage
for this part. Thus, using AISI 316 stainless steel and plain carbon steel is considered suitable
for this machine because of the high yield strength for both material but imposing the
11
Figure 9:The von mises stress of plain carbon steel for load 18.23 N
Figure 10: The von mises stress of plain carbon steel for load 150 N
12
Table 5:Table of resultant displacement for different materials and loads
Resultant Displacement
Materials Force, N
Minimum (mm) Maximum (mm)
AISI 316 Stainless 18.23 0 2.177 ×10−2
Steel Sheet (SS) 150.00 0 1.791× 10−1
18.23 0 2.005 ×10−2
Plain Carbon Steel
150.00 0 1.650 ×10−1
1.60E-01
1.40E-01
1.20E-01
1.00E-01
8.00E-02
6.00E-02
4.00E-02
2.00E-02
0.00E+00
18 N 150 N
Load (N)
Figure 11: The maximum resultant displacement for different loads and materials
Displacement is a vector at any point in the continuum figure and the components have x,
y, and z-directions. The maximum displacements of the frame happened at the end of the
critical parts for both material and both loads. This part has a higher tendency of
displacement due to lifting the hairlines and mould. With a force of 18.23 N, both AISI 316
stainless steel and plain carbon steel have maximum value of 2.177 x 10-2 mm and 2.005 x 10-
2
mm (Figure 12) respectively. This shows that the part will have slightly change of
movement with the load of 18.23 N. Despite that, imposing the chosen part to higher load
13
such as 150 N will affect the resultant displacement. The maximum displacement for 150 N
-1
when using plain carbon steel is 1.650 x 10 mm (Figure 13). The higher the resultant
displacement indicates that there will be greater value in movement distance from the initial
point. Although the resultant displacement is quite low when being imposed to 150 N, any
great load should be avoided as any changes in displacement may affect the efficiency of the
machine.
Figure 12:The resultant displacement analysis for plain carbon steel with 18.23 N
14
Figure 13:The resultant displacement analysis for plain carbon steel with 150 N
Table 6: Equivalent Strain from different material
Equivalent Strain
Materials Force, N
Minimum Maximum
AISI 316 Stainless 18.23 8.870 ×10−8 4.024 ×10−5
Steel Sheet (SS) 150.00 7.298 ×10−7 3.311 ×10−4
18.23 8.225 ×10−8 3.726 ×10−5
Plain Carbon Steel
150.00 6.768 ×10−7 3.066 ×10−4
3.00E-04
2.50E-04
Equivalnet Strain
2.00E-04
AISI 316 Stainless Steel Sheet (SS)
1.50E-04
Plain Carbon Steel
1.00E-04
5.00E-05
0.00E+00
18.23 N 150.00 N
Load, N
15
Table 6 summarizes the result of the equivalent stains obtained from different
materials with two different loads. The comparison will be done in 2 ways which is
comparison in terms of type of materials and in terms of different force applied. Comparison
between the type of materials shows that, the maximum equivalent strain for Stainless Steel
which is 4.024 ×10−5 is higher than Plain Carbon steel 3.726 ×10−5when 18.23 N force is
applied. This can be seen more clearly in (Figure 14), where the difference is relatively small
but still Stainless Steel will always have higher maximum equivalent strain compared to Plain
Carbon steel when 18.23 N and 150 N of force was applied. It proves those properties of
materials will affect the value of maximum strain obtained. However, a huge difference can
be detected when a different force is applied on the materials. When 18.23 N force is applied
on the Stainless Steel the value of maximum equivalent strain is 4.024 ×10−5 but higher
values of maximum equivalent strain which is 3.311 ×10−4 is obtained when 150 N force is
applied on the same materials. It shows that when force applied increases, the maximum
equivalent strain will also increase.
16
Figure 15: The equivalent strain analysis on plain carbon steel when 18.23N forces is
applied.
Figure 16: The equivalent strain analysis on plain carbon steel when 150N forces is applied.
The highest maximum stain area for both materials and loads are located at the screw
area where it is indicated by the green colour with slightly red colour around the screw area
(Figure 15). Besides, by comparing the intensity of light blue and green colour near to the
screw area from (Figure 15) and (Figure 16), it shows that at 18.23 N the green colour is
darker than at 150 N. The tendency for the area to damage, screw damage, and deterioration
are high. In addition, the area covered with light blue colour at 150 N is also bigger and
clearer compared to the area when 18.23 N force is applied. In this light blue colour region,
17
the compartment has a tendency to return back its original shape when the force is removed.
However, savage damage, fracture or deformation may occur if more force is applied.
Lubricant can be applied to help in reducing the stain intensity at the screw hole area and
prevent deformation or fracture. Thus, based on the overall result of the strain. It
demonstrates that when stress is applied, plain carbon steel has a lower risk of deformation
and fracture compared to stainless steel.
The overall result from the analysis shows a competitive trend in terms of mechanical
properties for both materials. The comparison between stainless steel and carbon steel can be
distinguished more in terms of its corrosivity. Carbon steel is high in carbon that when
exposed to moisture can corrode and rust quickly, but stainless steel has a high chromium
content which acts as a protective layer against corrosion and rust. Next in terms of
appearance, stainless steel can be given a particular finish if attractive appearance is desired
and does not tarnish easily while carbon steel is having less attractive appearance and cannot
achieve the finish of stainless steel. Next, aside from material properties, consideration in
terms or price also have to be done. By referring to Fastwell Engg. Pvt Ltd price list, the price
for AISI 316 Stainless Steel Sheet (SS) is Stainless Steel 316 is 3.72 USD/kg while the price
for carbon steel 2.048 USD/kg.
18
Calculation:
Q = A ý
π r2 4 r
Q= ×
2 3π
2 3
Q= r
3
2
Q= (0.00425)3
3
Q = 5.118 x 10-8
QV
Maximum stress,τ =
Ib
Where:
V = shear force
π D2 π r 4
I= =
64 4
QV 2 3 4 1
τ max= = r ×V ( 4 ) ( )
Ib 3 πr 2r
19
4V
τ max=
3A
Where:
A = π r 2 = π (0.00425 m)2
A = 5.675 ×10−5 m 2
Thus,
4(150 N )
τ max= = 3.52×10 6N/m2
3(5.675 ×10−5 m2)
Yield strength for AISI 316 Stainless Steel Sheet (SS) and Plain carbon steel, 1.72 x 108 N/m2
and 2.21 x 108 N/m2 respectively. Maximum shear stress of the condition applied is well
below the minimum yield stress.
20
21
CONCLUSION
In conclusion, the analysis of Von Mises Stress, resultant displacement, and
equivalent strain has shown that AISI 316 steel and plain carbon steel are both suitable for
this machine due to their high yield strength. However, subjecting them to higher loads may
damage the critical part. For elastic strain to occur and prevent permanent deformation of the
material, the maximum amount of stress applied to the material must be less than the
material's yield stress.
The critical part is the connector where the screw connects to the machine body and
this part is used to lift up the hairlines and mould. The activity of clamping the mould
repeatedly may result in damage to that part. AISI 316 stainless steel has higher tolerance of
Von Mises Stress with minimum value of 1.126 x 10 4 N/m2 to a maximum of 9.620 x 106
N/m2 compared to plain carbon steel. Plain carbon steel can resist more stress before
changing shape compared to AISI 316 stainless steel. When comparing based on different
loads, the load with 18.23 N has maximum Von Mises Stress, 9.617x 10 6 N /m2 while with
150 N load, maximum limit is 7.913 x 10 7 N/m2. Load of 150 N is considered to observe the
strength of the material and effect on the machine's part when being imposed to excessive
load. During the machine operation, this screw part is indeed the most critical part and the
greater the load will lead to higher damage for this part.
Furthermore, displacement is a vector at any point in the continuum figure and the
components have x, y, and z-directions. With a force of 18.23 N, both AISI 316 stainless
steel and plain carbon steel have maximum value of 2.177 x 10 -2 mm and 2.005 x 10-2 mm.
The higher the resultant displacement, the greater the value in movement distance from the
initial point. The load of 150 N should be avoided as any changes in displacement may affect
the efficiency of the machine.
Besides, when 18.23N and 150N of force were applied, AISI 316 stainless steel had a
higher maximum equivalent strain than plain carbon steel. It demonstrates that as the force
applied increases, the maximum equivalent strain increases as well. When a different force is
applied to the materials, a significant difference can be detected. It demonstrates how
material properties influence the maximum strain obtained. Although the difference is minor,
Stainless Steel will always have a higher total equivalent strain. As a result, based on the
strain's overall result. It demonstrates that plain carbon steel has a lower risk of deformation
and fracture when compared to stainless steel when stress is applied.
22
REFERENCES
6061 Aluminum: Get to Know its Properties and Uses - Gabrian. (n.d.). Retrieved June 8,
2021, from https://www.gabrian.com/6061-aluminum-properties/
Aluminium Alloy - Commercial Alloy - 6061 - T6 Extrusions. (n.d.). Retrieved June 8, 2021,
fromhttps://www.aalco.co.uk/datasheets/Aluminium-Alloy-6061-T6-
Extrusions_145.ashx
Ltd., T. (2021). What is the Difference Between Carbon Steel and Stainless Steel? - TWI.
https://www.twi-global.com/technical-knowledge/faqs/carbon-steel-vs-stainless-steel