Kulkarni et al, International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974

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Research Paper
FAILURE ANALYSIS AND WEIGHT OPTIMIZATION OF
CHAIN CONVEYOR SYSTEM
1
Hrishikesh Kishor Kulkarni, 2Prof.Dr.R.J.Patil

Address for Correspondence

1
Alard College of Engg, Hinjewadi, Pune,
2
Principal, D.Y Patil Institute of Engg. & tech., Ambi, Pune,
INTRODUCTION
Most of the time conveyor chain used in coal
transportation is under tension which causes failure
of chain assembly .This is found be a major problem
for industrial sector. The major causes
auses of this failure
are improper design of chain components as well as
improper selection. Historical data shows that the
chain link
ink is the major cause for conveyor chain
assembly failure. As conveyor assembly failure
results in huge losses for the user it is of paramount
importance to have a detailed analysis for the causes
of failures. Thehe objective of the current study is
addressing
ing the above mentioned problem statement.
This will include actual detailed industrial data which
ensure the study is as close as possible to the practice
situation. Using the actual data a chain link has been
design and analyzed thoroughly. Depending on the
Pune India
Pune India
results obtained the existing design will be compared
and modified to have a greater strength which will
result in more reliable and durable chains which will
result in decreased losses. In this study a shape
optimization process is also included for tthe design
of roller chain link, for maximization of yield
strength and weight reduction. This process has
various design variables, such as wall thickness of
link, material compositions of link, etc.
STATIC STRUCTURAL ANALYSIS ANALYSIS:
Apply loads and Solution:- (Load Considerations:
Tensile Load, Shock Load C. Inertia Load,
Centrifugal Tension)
Tensile force of 11679 N was applied to red face in X
direction. Element Size: - 5mm, Equivalent Stress:
- 151.91 Mpa, Total Deformation: - 0.00.02928 mm Fig.
Equivalent Stress (Element Size 5mm)

Fig. Total Deformation (Element Size 5mm)

Analysis Results:- case I-Hex
Hex Dominant Meshing Pattern:-
Element Size Equivalent Maximum Minimum Total Structural
(mm) Stress Principal Principal Deformation error (%)
Stress Stress (mm)
1 182.75 175.26 2.8664 0.03153 0.0000233
2 188.57 179.74 2.154 0.03686 0.00059215
3 178.25 175.3 2.0125 0.030371 0.0048804
4 175.44 175.52 1.2782 0.032931 0.033942
5 196.62 181.78 2.1891 0.028678 0.18044

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Analysis Results:- case I-tet

tet Dominant Meshing Pattern:-
Pattern:

DISCUSSION AND CONCLUSION drive the conveyor is going to be reduced

reduced. Hence, the
From the above results it is concluded that, as motor power is reduced. But the he design constraint
element size is increases from 1mm to 5mm the was strength of the link which sustain
sustains the direct
equivalent stress, total deformation values also vary. tensile load during the operation
operations. Since the
For hex dominant meshing pattern below is the composite
omposite materials have high strength to weight
summary:-Equivalent
Equivalent stress value is varying
vary from ratio and good corrosion resistance, the material
182.75 (Mpa) to 196.62 (Mpa) by varying element selected was glass fiber reinforced polymer (E (E-
size from 1mm to 5mm.Total .Total deformation value is glass/epoxy) and carbon epoxy xy which was used in
varying from 0.028678 (mm) to 0.03153 (mm) by place of conventional steel. The design parameters
varying element size from 1mm to 5mm.For 5mm Tet were selected and analyzed with the objective of
dominant meshing pattern below is the summary:-summary minimizing weight of the composite chain link as
Equivalent stress value is varying from 151.91 (Mpa) compared with the steel chain link [7]
[7].
to 182.55 (Mpa) by varying element size from 1mm Orthotropic Properties of Composites [7]:
[7]:-
to 5mm.Total deformation value is varying from Epoxy with link Thickness 15 mm:mm:-
0.02928 (mm) to 0.0312 (mm) by varying element Tet Dominant Pattern:-Element
Element Size = 1 mm No. of
size from 1mm to 5mm.It It is inferred from the above Nodes:-938677, Equivalent Stress = 250.08 Mpa,
analysis that for every case undertaken for the Total deformation = 0.0365mm
analysis the equivalent stress generated in the
element during the analysis is well below the tensile
yield strength (250 Mpa) of the selected material
(Structural Steel) for both the meshing pattern i.e.
Hex dominant and Tet dominant [9].. Therefore, it can
be safely concluded from above findings that selected
chain type is perfectly suitable for safe usage to
handle current force condition. It is also found that
Tet dominant meshing pattern generates satisfactory
results.. On the other hand the same level of accuracy
is reached in Hex dominant meshing pattern while it
generated considerably less number of nodes. nodes
Therefore it is found that Tet meshing pattern is
computationally expensive while comparing with the
latter. One more interesting inference from the
analysis undertaken is that percentage structural error
increases if element size is increased. Therefore we
resort to using 1mm element size for further
calculations as this leads to stiffness in generated
elements which is in line with the actual results.
Optimization in existing design: Reducing weight
while increasing or maintaining strength of products
is highly important. The aim was to optimize the
chain assembly by reducing the weight of the chain cha
link through material changes. As self-weight
weight of the
chain assembly gets reduced then force required to
Glass Fiber (E-glass/epoxy) Composite Material
Thickness Equivalent Maximum Minimum Total Weight
of link Stress Principal Principal Deformation (kg)
(mm) Stress Stress (mm)
5 386.0 384.55 2.3507 0.2321 0.051
10 186.0 186.81 1.8864 0.1168 0.102
15 128.3 129.26 1.4446 0.0732 0.153

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Carbon Epoxy Composite Material

Thickness Equivalent Maximum Minimum Total Weight
of link Stress Principal Principal Deformation (kg)
(mm) Stress Stress (mm)
5 786.2 786.53 3.377 0.1129 0.040
10 357.8 358.11 2.080 0.0565 0.081
15 250.0 251.43 1.555 0.0365 0.122

Total No. Of chain link:-

Percent Weight Saving:-Total link: The deformation values when considering 15mm

 ∗ 
 length  π ∗  
 ∗  ∗ 
  π ∗ links of both the material was found to be
,= ,=
  approximately equal to that of the deformation found
489.17 = 490 ….by adding adjustable link ,D = Dia. in steel. Therefore as the values were approximately
Of the Sprocket wheel.,P P = Pitch of the link,total
link equal,, the analysis selected 15mm thickness of links.
weight of the Chain Link = No Of chain link * weight When considering 15mm thickness of links of all the
of one link.Case-I: - Total Weight of chain link using materials, it was found that steel link weighed 98kg
Steel:-Total weight of the Chain Link = 490 * in comparison E-glass
glass epoxy weighed 75.11kg which
0.200,=98kg,Case-II: - Total Weight of chain link resulted in 23.35% weight reduction. Similarly the
using Glass Fiber (E-glass/epoxy):-Total
Total weight of Carbon Epoxy weighed 59.78kg which resulted in
the Chain Link = 490 * 0.15333,= 75.11kg,Case-
75.11kg 39% weight reduction.
II: - Total Weight of chain link using Carbon Epoxy:-
Epoxy: CONCLUSION
Total weight of the Chain Link = 490 * 0.122,= It is also found that Tet dominant meshing pattern
59.78kg generates satisfactory results.. On the other hand the
Table shows the % saving of weight by using same level of accuracy is reached in Hex dominant
composites instead off steel. meshing pattern while it generated considerably less
Sr Materials Weight % Weight number of nodes. Tet meshing pattern is
No. (kg) Saving computationally expensive while comparing with the
1 Steel 98 - Hex Dominant pattern for the given study.
2 E-glass/epoxy 75.11 23.35 Percentage structural error increases if the element
size is increased. Error is found out to be at minimum
3 Carbon Epoxy 59.78 39
level for element size 1mm.Hexx Dominant meshing
DISCUSSION AND CONCLUSION pattern with 1mm element size is preferred, which is
The detailed analysis of different composite materials in line with the actual results. It was also revealed
i.e. E-glass/epoxy
glass/epoxy and Carbon epoxy has revealed that, for every case undertaken for the analysis the
certain distinct points which are listed below:-
below: equivalent stress generated in the element is well
• For E-glass epoxy, as the thickness is increased below the tensile yield strength
rength of the selected
from 5mm to 15 mm, the equivalent stress material (Structural Steel) for both the meshing
generated in the link is varying from pattern i.e. Hex dominant and Tet dominant.
386.01Mpa to 128.3 Mpa. All the stresses Therefore, it can be safely concluded from above
generated here are below the ultimate tensile findings that selected chain type is perfectly suitable
strength (1500 Mpa) of the material considered for safe usage to handle current force
rce condition. After
[9]. The deformation
ation was found out to be analysis was completed a detailed optimization
decreasing steadily from 0.23217mm to process was undertaken using E-glass glass epoxy and
0.073205mm. Carbon epoxy. The working condition in both the
• For Carbon epoxy, as the thickness is increased materials was kept same. However the stress and the
from 5mm to 15 mm, the equivalent stress deformation in the composite materials of 5mm
generated in the link is varying from 786.26 thickness was found to be greater than the steel link
Mpa to 250.08 Mpa. All the stresses generated deformation. To counter this problem the thickness of
here are below the ultimate tensile strength the link was increased to 15 mm. In this case, it was
(1600 Mpa) of the material considered [9]. The found that the stress generated in E--glass epoxy was
deformation was found out to be decreasing less than the stress generated in thee steel link whereas
steadily from 0.11295mm to 0.036593mm. stress generated in Carbon epoxy was higher than the
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steel link. Hence it was concluded that E-glass epoxy

was the best alternative to the steel link as it was safe
and at the same time resulted in 23.71% weight
saving.
REFERENCES
1. Tushar D. Bhoite, Prashant M. Pawar & Bhaskar D.
Gaikwad, “FEA Based Study of Effect of Radial
Variation of Outer Link in A Typical Roller Chain Link
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2012.
2. Sran M. Bosnjak, Miodrag A. Arsi, Nenad Zrni, Zoran
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3. Nenad D. Zrnic, Srdan M. Bosnjak, Vlada M. Gasic,
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