ANALYSIS AND OPTIMAISING

OF PNEUMATIC LOADER ARM

USING Pro-E AND ANSYS
PROJECT DONE BY
K.KAPILRAJ
V.SARAVANAN
R.SIDHARTHAN
INTRODUCTION
The pneumatic high-speed loader is employed to load
and unload the auto components in high- speed metal
forming press machine.
The high-speed pneumatic arm is mounted on the
vertical saddle and has rapid movement in and out of
the machine.
A travel time of 1500mm is completed in less than 1.2
sec, hence the name of high-speed loader is given to it.
Completing a loading cycle in complete 3 sec.
OBJECTIVE
Hence the task was to optimize the loader arm from
stress and deflection point of view.
In this process we creating the model of the loader
arm in Pro-E and importing to Ansys software.
In the ansys software it’s optimized to minimum
deflection
Images of the loader arm in different position
as shown below
Description of the loader arm
The loader arm is made up of hollow tubular pipes of
mild steel (MS) having internal diameter of 30mm and
thickness of 4mm
The loader is mounted on the vertical saddle. It rapid
loading movement in and out of the press machine.
The loader arm also has up and down motion to pick
and place the metal sheet in and out of the press
machine
Material Properties:
Young’s Modulus = 200000 N/mm2

Poision’s Ratio = 0.3

Creating
the part in
Pro-E
Using Pro-E software
the model was
created
Importing the part
Thus the created part is saved in IGS file format
Then the part was imported to Ansys software
The model is discertized and meshed to analys the
stress and deflection.
The process have done in ansys software as shown
below
Below fig shows the application of degree of
freedom on the structure of loader arm
The application of the force load on the
limbs of the loader arm
Application of both Degree of Freedom and
Load
 Result for Original
Design

The following where the

graphical output obtained
when the ANSYS program
was run.

This shows the various

stresses acting on the
loader arm.

An axial stress is

96.721N/mm2
Bending stress of 98.016 N/mm2 is seen in the loader
arm during the ANSYS
A Deflection of 13.276mm is seen in the loader arm in the below
figure
Hence the result
obtained by the above
analysis are as follow:
Max Deflection = 13.276mm

Max Bending stress =

98.016N/mm2

Max Axial Stress =

96.721N/mm2

Max Von Mises stresses =

96.967N/mm2
Optimization
Optimization plays crucial role in enhancing the
performance of any product and it is also important
from economic point of view.
It helps to get best possible design from the original
design
The initial calculation results shows shows a level of
deflection considered as not safe for the loader arm.
Therefore it was decided to reduce the deflection to
the least possible, while keeping all the stresses within
the safe elastic limits
Stages of optimization
First stage of optimized
here changing the position of the link in the
arm from its original position that is when the position
of the link is at 1073.6mm from the reference point ,to
the position of 1342mm.
Second stage of optimization we will change the
position link from 1073.6mm, which was taken for
performing the first stage of optimization, to a
position 2147.2mm from the reference point
Optimized object in first stage
After optimizing the axial stress induced in the loader arm when
the structural geometry of the arm is changed found to be
71.22 N/mm2
Bending stress of 71.237 N/mm2 is seen in the
loader arm when the geometry was changed
A Deflection of 7.698mm is seen in the loader
arm in the below figure
Hence the result
obtained by the above
analysis are as follow:
Max Deflection = 7.698mm

Max Bending stress =

71.237N/mm2

Max Axial Stress =

71.22N/mm2

Max Von Misses stresses =

71.223N/mm2
Optimized object in Second stage
After optimizing the axial stress induced in the loader arm when
the structural geometry of the arm is changed found to be
30.329 N/mm2
Bending stress of 48.399 N/mm2 is seen in the
loader arm when the geometry was changed
A Deflection of 2.971mm is seen in the loader arm in the
below figure after the geometry was changed
Hence the result
obtained by the above
analysis are as follow:

Max Deflection =
2.971mm

Max Bending stress =

48.399N/mm2

Max Axial Stress =

30.329N/mm2

Max Von Misses stresses =

48.212N/mm2
Comparison of Results
Original First Second
Design Optimizatio Optimizatio
n n
Max
13.276mm 7.698mm 2.971mm
Deflection
Max Bending
98.016N/mm2 71.237N/mm2 48.399N/mm2
stress
Max Axial
96.721N/mm2 71.220N/mm2 30.329N/mm2
Stress
Max Von
96.967N/mm2 71.223N/mm2 48.212N/mm2
Misses
stresses
Future Work
The current work only deals with the static analysis of
the loader arm of the pneumatic loader.
The future scope of the work can include the dynamic
analysis of the loader arm
Conclusion
The main intension of the work was carry out the
optimization of the loader arm. For this purpose Pro-E
and ansys software is used.
The simulation were carried out of great importance as
it elimination manufacturing time and physical effort.
Finally the changes made during the optimization were
found to increase the performance of the loader arm
A future scope of the work can include dynamic analysis
of the loader arm
THANKING
YOU