FINAL PROJECT REPORT

DESIGN PROCESS PLANNING & MANAGEMENT

AKASH KONAR – 20BME0024

VEDANT KULKARNI – 20BME0030
ADVAIT BAWDEKAR – 20BME0076
IMRAN ANEES – 20BME0660
TABLE OF CONTENTS

IMPORTANCE OF PROBLEM STATEMENT..........................................................................................................3

OBJECTIVES........................................................................................................................................................3
BACKGROUND STUDY........................................................................................................................................4
LITERATURE REVIEW..........................................................................................................................................4
DESIGN METHODOLOGY....................................................................................................................................6
CONCEPT GENERATION AND SCREENING.........................................................................................................6
FINAL DESIGN.....................................................................................................................................................9
MANUFACTURING PARAMETERS....................................................................................................................10
MATERIAL SELECTION......................................................................................................................................11
MANUFACTURING TIME..................................................................................................................................11
TOOLS AND MACHINING REQUIRED...............................................................................................................11
IMPORTANCE OF PROBLEM STATEMENT
In industrial ventilation systems, direct drive fans are prone to a serious problem known as Foreign
Object Damage (FOD). This issue can cause the rotor to break off, potentially causing harm to other
crucial components within the system. To prevent this from happening, a metal ring is installed
around the rotor to help contain any potential damage caused by the broken rotor.
However, the metal ring itself must be able to endure high impact stresses. To achieve this, the
rings are usually constructed with a solid cross-section, which ultimately adds unnecessary weight
to the ventilation system. Consequently, it is our goal to optimize the ring's design and minimize its
weight while ensuring it can still withstand high impact stresses. This approach will improve the
performance of the ventilation system and reduce the risk of any further damage caused by the
rotor or its surrounding components. By reducing the weight of the metal ring, we can help to
increase the overall efficiency of the ventilation system and minimize any potential downtime or
repair costs. Thus, optimizing the design of the metal ring is a crucial aspect of improving the overall
performance of the industrial ventilation system.

OBJECTIVES
1. Material Selection
Choosing the best material is paramount. A material with high strength to weight ratio is
ideal while being cost effective.
2. Identifying Process Parameters
Identifying the nature and location of loads in the component. The component should be
able to withstand high impact stresses, but should not break/fail.
3. Weight Optimisation
Incorporating Weight optimization techniques to reduce weight which keeping the
structural integrity.
4. Design Verification
Verifying that the optimized ring is able to withstand the given loads. FEA will be used and
verification and further iterations.
5. Identifying Manufacturing Process
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BACKGROUND STUDY
Extensive research was conducted by examining numerous literature papers to identify the most
suitable material for the problem statement. The investigation focused on various materials, with a
particular emphasis on Inconel 625. The material was found to possess numerous desirable
qualities, including high tensile stress and excellent corrosion resistance.
Next, the relevant material data was extracted to predict the behaviour of Inconel 625 across a
range of loads. This was achieved by interpolating the S-n Curve for the material, allowing for an
accurate anticipation of its performance under different conditions.
A variety of lattices were also studied to optimize the approach further. The weight and behaviour
of each lattice were assessed under different loads to identify the lattice that best suited the
specific needs of the project. A thorough analysis of the structural characteristics of each lattice,
including stiffness, strength, and durability, was conducted.
Ultimately, this approach led to the selection of the optimal material and lattice for the particular
problem statement. By leveraging the unique properties of Inconel 625 and carefully considering
the performance of various lattices, an effective and efficient solution was developed. This
approach will aid in minimizing costs and maximizing the performance of materials, resulting in a
more successful outcome for the project.

LITERATURE REVIEW
Year of Method of
Sr. No. Title Authors Journal Findings
Publication Research
1 Design and Gupta et al. 2020 Journal of Experimental The use of a metallic
development Mechanical fan casing resulted in
of a metallic Engineering improved durability
fan casing for and Sciences and increased fan
industrial efficiency.
ventilation
 applications
Optimization
of a metal
ring design The optimized metal
for an Journal of ring design resulted
industrial Mechanical Numerical in improved fan
2 Cho et al. 2019
ventilation Science and simulation efficiency and
fan using Technology reduced vibration
finite levels.
element
analysis
Design and
The metal ring design
analysis of a Journal of
Numerical resulted in improved
3 metal ring for Zheng et al. 2017 Mechanical
simulation fan efficiency and
an industrial Engineering
reduced noise levels.
axial flow fan
Design and
analysis of a The metal ring design
Journal of
metal ring for was able to
Thermal
a high- withstand high
4 Zhang et al. 2018 Science and Experimental
temperature temperatures and
Engineering
industrial improve fan
Applications
ventilation efficiency.
fan
Design and
The optimized metal
optimization International
ring design resulted
of a metal Journal of
Numerical in improved fan
5 ring for an Wang et al. 2016 Heat and
simulation efficiency and
industrial Mass
reduced vibration
centrifugal Transfer
levels.
fan
Experimental
and
numerical
International
study of
Journal of The stiffness of the
metal ring
Precision Experimental metal ring had a
stiffness on
6 Lee et al. 2015 Engineering and numerical significant impact on
the
and simulation fan efficiency and
aerodynamic
Manufacturi noise levels.
performance
ng
of a
centrifugal
fan
Design and
analysis of a
The optimized metal
metal ring for
Applied ring design resulted
an industrial Numerical
7 Liu et al. 2014 Thermal in improved fan
ventilation simulation
Engineering efficiency and
fan with
reduced noise levels
backward-
curved blades
Investigation
of the effect
of metal ring The thickness of the
Applied
thickness on metal ring had a
Mechanics
8 the Sun et al. 2013 Experimental significant impact on
and
performance fan efficiency and
Materials
of a vibration levels.
centrifugal
fan
9 Design and Huang et 2012 Journal of Numerical The optimized metal
optimization al. Thermal simulation ring design resulted
 of a metal
ring for an
industrial in improved fan
Science and
ventilation efficiency and
Technology
fan with reduced noise levels.
forward-
curved blades
Structural
analysis and The optimized metal
optimization Applied ring design resulted
of metal ring Mechanics Numerical in improved fan
10 Zhang et al. 2011
for an and simulation efficiency and
industrial Materials reduced vibration
centrifugal levels.
fan

DESIGN METHODOLOGY
In the process of designing a component, it is imperative to identify the primary forces that act
upon it to ensure its ability to withstand the intended load. To achieve weight optimization, the
strategy was to remove excess material from areas where the forces have less magnitude or are not
present. This approach is aimed at reducing the weight of the component while maintaining its
strength. Iterations were done with varying parameters such as thickness and density of the lattice
and the ones showing the best strength to weight ratio would be selected for further analysis. By
adopting this iterative approach, a final design was achieved that satisfies both the required
strength and weight specifications, guaranteeing optimal performance in its intended application.
After gathering the required data, we proceeded to analyse the basic ring model using Ansys
Structural to carry out the Von-Mises stress analysis to determine its maximum stress formed and
Fatigue Analysis to determine its Factor of Safety as shown below.

Through the above analysis we got to know stress is not exceeding the yield strength of the
material, hence not failing. Preliminary topology optimization on the model was performed based
on this data.

CONCEPT GENERATION AND SCREENING

From the results of the basic ring model, one can figure out that stress is mainly concentrated on
the area where pressure is applied. As a result, lattice structure was implemented in low stress
acting regions rather than high stress acting parts. A quantitative trade off was then performed on 4
lattice iterations of the ring by performing stress and deformation analysis on nTopology.
1. Discontinuous Lattice:

Weight 405.83 g
Maximum Stress 446.68 MPa
Total Deformation 0.0406 mm
Factor of Safety 1.03

2. Square Lattice:

Weight 279.64 g
Maximum Stress 737.82 MPa
Total Deformation 0.148 mm
Factor of Safety 0.623
3. Hexagonal Honeycomb (VUW):

Weight 342.39 g
Maximum Stress 433.47 MPa
Total Deformation 0.0523 mm
Factor of Safety 1.061

4. Hexagonal Honeycomb (UVW):

Weight 329.89 g
Maximum Stress 441.83 MPa
Total Deformation 0.15 mm
Factor of Safety 1.041
TRADE STUDY

(VUW) Hexagonal
Honeycomb

(UVW) Hexagonal
Honeycomb

Sqaure Lattice

Discontinous Lattice

Base Ring

0 0.1 0.2 0.3 0.4 0.5 0.6

Deformation Weight

(VUW) Hexagonal
Honeycomb
(UVW) Hexagonal
Honeycomb

Sqaure Lattice

Discontinous Lattice

Base Ring
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

F.O.S.

FINAL DESIGN
Upon conducting simulation on various lattice structures, Honeycomb Structure with VUW
orientation was chosen due to its high strength to weight ratio. The hexagonal lattice has the lowest
anisotropy of all regular two-dimensional lattices. Often this lower anisotropy makes simulations
appear more natural. The honeycomb gives higher consistency and strength across the ring,
resulting in increased strength and stability.
We arrived at the final design after performing extensive analysis and eliminating lattices that were
not in nature. The final design had benefits of both the hexagonal honeycomb lattice and adequate
strength to handle the pressure acting on it.
We obtained:

 A final weight of 342.39 Kg, which is a 30% reduction in weight

 A F.O.S of 1.061
 A Maximum stress of 433.7 MPa which is lower than the yield stress 460 MPa
As these points prove that the design doesn’t break/fail under the given loading conditions while
maintaining a lightweight design, thus satisfying the problem statement.

MANUFACTURING PARAMETERS
To manufacture the given part with high precision and accuracy, Fused Deposition Modelling was
chosen as the Manufacturing Process. The material chosen was Carbon Fibre Reinforced Nylon PA6
as it has a high strength to weight ratio and great printability using FDM process. Creality Ender 3
Pro can be used to print the given component. Ultimaker Cura was used to slice the component
and generate the Gcode.

https://drive.google.com/drive/folders/1KNm4--NqrmeaaM5D_971I-7LzJmRL5Gw?usp=share_link
Parameter Value
Nozzle Tempertaure 270 °C
Bed Temperature 110 °C
Printing Speed 60 mm/s
Filament Carbon Fiber Reinforced Nylon PA6

MATERIAL SELECTION
Carbon fibre nylon is a high-strength substance that can handle significant loads and stresses and
also offers good stiffness. For lattice structures that need to have high strength-to-weight ratios,
this makes it perfect.

 Lightweight: As compared to other high-strength materials like metals, carbon fibre nylon is
also comparatively lightweight. As a result, it is a viable option for uses where weight
reduction is crucial, including in the aerospace and automotive industries.
  Compatible: Carbon fibre nylon is a material that is compatible with FDM 3D printing and is
thus a good option for producing lattice structures with this technique. FDM is a well-liked
manufacturing technique with good precision and repeatability that is readily accessible.
 Cost-effective: Compared to certain other high-strength materials, carbon fibre nylon is a
more affordable material, making it an excellent option for applications where price is an
important factor.
In conclusion, Carbon Fibre Nylon is a solid material selection for the FDM method when making a
ring with a lattice structure. It is lightweight, has high rigidity and strength, is compatible with FDM
3D printing, and is reasonably priced.

MANUFACTURING TIME
Ultimaker Cura is used to slice the component and obtain the G-Code. The exact time required for
printing the component is provided by the software. According to the G-Code, the time taken for
manufacturing the required component using Creality Ender 3 Pro is 21 hours and 18 minutes. The
manufacturing time depends on the printing and travel speed of the printer specified before slicing.
Faster printing and travel speed will lead to lower manufacturing time required. The time
mentioned above does not include printer setup time which may include activities like preheating
the printer, filament loading, etc.

TOOLS AND MACHINING REQUIRED

3D printing of the ring using FDM with Carbon Fibre Nylon material, the following tools and
machines are required:

 FDM 3D Printer: An FDM 3D printer is required to manufacture the ring. The printer should
have a heated build plate and an extruder capable of printing with Carbon Fibre Nylon. The
FDM 3D printer used is Creality Ender 3 Pro.
 Slicing Software: Slicing software is used to convert the 3D model of the ring into machine-
readable code that the printer can understand. The software also allows you to configure
printing parameters such as layer height, infill density, and print speed.
 3D Modelling Software: A 3D modelling software, Ultimake Cura is required to design the
ring with a lattice structure.
 Carbon Fibre Nylon Filament: Carbon Fibre Reinforced Nylon PA6 filament is required to
print the ring. It is recommended to use high-quality filament that is specifically designed for
FDM printing to ensure good print quality and dimensional accuracy.
 Post-Processing Tools: After printing the ring, post-processing may be required to remove
any support structures or rough edges. You may need sandpaper, files, or other tools to
smooth out the surface of the ring.
Overall, these tools and machines are required to manufacture a ring with lattice structure using
FDM 3D printing with Carbon Fibre Nylon. As a result, a high-quality and strong lattice structure ring
can be produced using FDM 3D printing technology.