Analysis of Residual Stresses In A Butt Weld Using Ansys

Software (Models And Analysis Is Require)

Low carbon steels are prone to distortion and cracks due to residual stresses induced during
welding. This project gives the information about the residual stresses induced in a butt weld
joint due to welding. Experimentation was carried out on a plate made of low carbon steel having
dimensions 0.115 x 0.048 x 0.006 meters. The type of welding chosen is Manual Metal Arc
Welding (MMAW). Single pass welding was carried out. Experimental values calculated were
taken as input for the analysis in ANSYS software.

A model was generated in ANSYS 13.0 (A general purpose FEA software) using SOLID BRICK 8 NODE
70 (3D solid element with temperature dof) and PLANE 55 (A 2D Solid Element with 4 nodes), as per the
dimensions of the plate taken for the experimentation. A refined mesh is made based on the
convergency criteria and the analysis is performed to estimate the temperature distribution. Firstly a
transient thermal analysis was carried out by giving heat flux as the time varying input to estimate the
temperature variation. The non-linear material properties are fed for the heat transfer solution. Then
coupled field analysis is carried out to get the residual stresses by coupling thermal analysis to static
analysis. The variation of the temperature with time, and residual stresses are obtained. The variation of
these are reported and discussed.
 STATIC AND DYNAMIC ANALYSIS ON COMPOSITE LEAF SPRING IN
HEAVY VEHICLE

Leaf spring are of the oldest suspension component they are still frequently used. The current
leaf spring is multiple leaf spring types with a steel material. It has high weight, low natural
frequency, high corrosion, more noise. Therefore current multiple leaf spring is replaced by
mono composite (E- Glass epoxy) leaf spring which has high natural frequency, low weight etc.
The maximum stress produced at the cylindrically joint than fixed
joint. Therefore stress analysis of composite material mono leaf spring is carried out. The result
of finite element method is verified with analytical calculation. Also compare the natural
frequency by FEA.

In order to conserve natural resources and economize energy, weight reduction has been the
main focus of automobile manufacturers in the present scenario. Weight reduction can be
achieved primarily by the introduction of better material, design optimization and better
manufacturing processes. The suspension leaf spring is one of the potential items for weight
reduction in automobiles as it accounts for 10% - 20% of the unstrung weight. This achieves the
vehicle with more fuel efficiency and improved riding qualities.

According to the studies made a material with maximum strength and minimum modulus of
elasticity in the longitudinal direction is the most suitable material for a leaf spring. Fortunately,
composites have these characteristics. In the present work, a seven-leaf steel spring used in
passenger cars is replaced with a composite multi leaf spring made of glass/epoxy composites.
The dimensions and the number of leaves for both steel leaf spring and composite leaf springs
are considered to be the same. The primary objective is to compare their load carrying capacity,
stiffness and weight savings of composite leaf spring. Finally, fatigue life of steel and composite
leaf spring is also predicted using life data. The objective of this paper is to calculate stresses,
strength to weight ratio, dynamic loading condition, and stiffness & compare those with
conventional steel leaf spring.

For the accurate evaluation of above factor we use Finite Element Method. In Static analysis,
there is no variation of force with respect to time. Output in the form of stress, displacement, etc.
with respect to time is not taken into account. Modal analysis of leaf spring is conducted to study
the natural frequencies
STATIC AND DYNAMIC ANALYSIS OF COMPOSITE TURBINE BLADES

Blades are being developed in composite materials in order to achieve low-

weight and high strength construction. Composite blades are made with unidirectional

fibers parallel to the blade’s long axis, as well as adaptive configurations, with fiber

orientation in off-axis directions to effect bend-twist coupling developing concept

designs and analyzing the structural response of composite blades for different

operating conditions is taken up in this project.

In the first stage the model of the turbine blade is created with the specified

design parameters using PRO-E modeling software and these models are used for the

analysis part.In this analysis,

a 2D model of the rectangular turbine blade has been considered and has been

meshed using LINEAR LAYER99 structural shell element. A load of 1041.83*10-3 N/mm2

is applied on the surface of the blade and the root of the blade has been constrained in

all degrees of freedom. The analysis has been carried out under these constraints.

Different cases were taken up to estimate the values of deformations and stress values

by altering the thickness of blade and angle of twist the blade. Initially the work is

carried out for 0 degree, 15 degree and then for 45 degree twist in blade construction by

taking two different thickness values 7mm and 5mm respectively. Modal analysis was

done to extract the natural frequencies of vibration for all the above cases and

extracting their mode shapes. The thesis report gives details about the geometry of the

turbine blade, material, and analysis of turbine blades.

Crank Shaft Design And Analysis Using Forged Steel And Ductile Cast Iron

The overall objective of this project was to evaluate and compare the fatigue
performance of two competing manufacturing technologies for automotive crankshafts,
namely forged steel and ductile cast iron.
In this project a dynamic simulation was conducted on two crankshafts, forged
steel and ductile cast iron, from similar four cylinder four stroke engines. Finite element
analysis was performed to obtain the variation of stress magnitude at critical locations.

The pressure-volume diagram was used to calculate the load boundary condition
in dynamic simulation model, and other simulation inputs were taken from the engine
specification chart. The dynamic analysis was done analytically and was verified by
simulations in ANSYS.

Results achieved from aforementioned analysis were used in optimization of the

forged steel crankshaft. Geometry, material, and manufacturing processes were
optimized considering different constraints, manufacturing feasibility, and cost.

The optimization Process included geometry changes compatible with the current
engine, fillet rolling, and the use of micro alloyed steel, resulting in increased fatigue
strength and reduced cost of the crankshaft, without changing connecting rod and or
engine block.
Design and Dynamic Analysis of Truck Chassis Frame Using FEA

The present scenario in automotive industry is an increase in demand of trucks not only
on the cost and weight aspects but also on improved complete vehicle features and
overall work performance. The chassis plays an important role in the design of any
truck.

The chassis design in general is a complex methodology and to arrive at a solution

which yields a good performance is a tedious task. Since the chassis has a complex
geometry and loading patterns, there is no well defined analytical procedure to analyze
the chassis. So the numerical method of analysis is adopted, in which ‘Finite Element
Technique’ is most widely used method.

The main objective of this work is to evaluate static and dynamic characteristics of a
truck chassis under different load conditions. Geometric modeling of the various
components of chassis has been carried out in part mode as 3-D models using CATIA
V5.

These properties have been used as input while performing the Finite Element Analysis
using ANSYS.In this Project we have compared the Chassis Frame by using two
materials i.e. Stainless steel and BSK 46 steel by doing static and modal analysis.