Design and of Gear Control Box Base Plate Made of Polymer Analysis Composite Material through CAE

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Design and of Gear Control Box Base Plate Made of
Polymer Analysis Composite Material through CAE
Presented By,

1. Kiran Thore
2. Vikas Patil
3. Vivek Kadu

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Outlines

• Introduction.
• Part Design.
• FEA Modeling.
• Quality Checks.
• Linear Analysis.
• Thermal Analysis.
• Results Discussion.
• Conclusion.
• References.

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Introduction

• Composite Material
• material consisting of more than one
  macroscopic phase

matrix, disperse phase, interface
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Categories

• Subdivision by

Matrix material Polymer matrix composite PMC
Metal matrix composite
MMC Ceramic
matrix composite CMC
Disperse phase particles,whiskers,short fibers,
Continuous fibers, sheet laminates
random/ preferred orientation Isotro
pic/anisotropic

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Why Composites for Cars?
Glass Fiber Composites can reduce weight by 20
-30
Data Base
Design Methodologies
Processing Technologies
Material Crash Models
Rapid Cure Technologies
Joining Methods
NDT
Recycling
Carbon Fiber Composites can reduce weight by
40-60
Weight Reduction Fuel Economy Emission
Reductions
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Automotive Light weighting Material

• Largest Focus Areas
• Polymeric-matrix composites processing
• Aluminum sheet formation and fabrication
• Aluminum and magnesium casting

• Missions
• Support development of cost-effective materials
  and materials manufacturing processes required to
  achieve successful commercial introduction of
  fuel-efficient, low-emission, terrestrial
  transportation vehicles.

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Weight Savings and Costs for AutomotiveLight
weighting Materials
Lightweight Material MaterialReplaced Mass Reduction ()
High Strength Steel Mild Steel 10
Aluminum (AI) Steel, Cast Iron 40 - 60
Magnesium Steel or Cast Iron 60 - 75
Magnesium Aluminum 25 - 35
Glass FRP Composites Steel 25 - 35
Graphite FRP Composites Steel 50 - 60
Al matrix Composites Steel or Cast Iron 50 - 65
Titanium Alloy Steel 40 - 55
Stainless Steel Carbon Steel 20 - 45
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Project Component
Base Plate
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Part Design

• Original Design.
• Modified design (features modified in the
  component)
• Thickness control.

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Original Design
1. Solid Model is Generated using CATIA V5 R16.
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Modified Component

1. Wall Thickness is increased taken 7mm.
2. Rib is generated in front wall.
3. Side Wall height is increased.

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Drafting of Modified Component
Side View
Top View
Front View
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Comparison between original modified model
Modified model
Original Model
Rib is Inserted
Wall thickness is increased
Side wall Height is increased
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Material Detail

• Required material Properties
• High impact resistance
• High temperature
• Dimensional stability
• Chemical resistance
• Stiffness
• Wear resistance
• Part weight

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Structural grade Epoxy 50 Glass Fiber
Reinforced material. Commercial name Vyncolit EM
7302 Hardware Grade Epoxy. Manufacturer sumitomo
Bakelite Phenolics (USA).
Mechanical Properties Metric
Hardness, Rockwell M 105
Tensile strength at Break 138 Mpa
Flexural Modulus 24.0 Gpa
Flexural Strength 345 Mpa
Compressive Strength 255 Mpa
Izod Impact, Notched 16.0 j/cm
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Electrical Properties Metric
Dielectric Constant 5.80
Dielectric Strength 12.8 kV/mm
Dissipation Factor 0.0170
Arc Resistance 120 Sec.
Thermal Properties Metric
CTE, Linear 20ºC 120 µm/m-ºC
Thermal conductivity 0.420W/m-K
Deflection Temperature At 1.8Mpa gt250 ºC
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Physical Properties Metric
Density 1.85 g/cc
Linear Mold shrinkage 0.00100 cm/cm
Descriptive Properties Metric
Color Black Natural
Main Filler Glass Fiber
Molding Method Compression, Transfer
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Methodology Strategy of Analysis
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FEA Modeling

• Mesh details
• Hypermesh 8.0 platform is used for meshing.
• FE model generated on mid surface of component.
• Mixed elements (Quad Tria) are used for
  meshing.
• 2D Shell elements are used (2D shells can be
  drawn as a line, 3D as an area.)
• Average 4.0 mm min 2.0 mm element size is
  considered.
• Washer is created near holes.
• Dense meshing near hole areas.

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Quality Checks
Quality is checked on different parameters
warpage, aspect ratio, length jacobian
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lt Aspect Ratio This is the ratio of max element
edge length to minimum edge length. Ideal value
1 (Acceptable is less than 5)
Jacobean Check gt Ideal Value 1.0 (Acceptable
more then 0.6) Jacobian is a scale factor
arising because of transformation of co-ordinate
system.
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warpage Check Warp angle is out of plane
angle. Ideal value 00 (Acceptable is less
than 100 )
Element length Average 4.0mm Maximum 6.00
mm Minimum 2.00 mm
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FREE EDGES CHECKING Any quad element having 4
free edges
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Boundary Condition Details
Essential and Natural B.C. Boundary conditions
(BCs) come in two basic flavors essential and
natural. Essential BCs directly affect DOFs.
Natural BCs do not directly affect.    1. If a
boundary condition involves one or more degrees
of freedom in a direct way, it is
essential. An example is a prescribed node
displacement. 2. Otherwise it is natural.    
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  Boundary Conditions in Structural
Problems   Essential boundary conditions in
mechanical problems involve displacements (but
not strain-type displacement derivatives).
Support Conditions   Supports are used to
restrain structures against relative rigid body
motions. The resulting boundary conditions are
often called motion constraints.
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Natural B.C.
Essential B.C.
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Linear Analysis

• Analysis is performed in optistruct 8.0, package
  of hyper-works.
• Analysis has been carried out for different
  amount of loads such as 1 N, 2 N, 3 N, 4 N, 5 N
  10 N
• Displacement of the component and von-mises
  stress is found out for different amount of loads

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1 N of Load
Displacement
Von Misces stress
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2N of Load
Displacement
Von Misces stress
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3 N of Load
Displacement
Von Misces stress
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4 N of load
Displacement
Von Misces stress
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5 N of Load
Displacement
Von Misces stress
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10 N of Load
Displacement
Von Misces stress
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Thermal Analysis

• Thermal analysis is performed in optistruct 8.0.
• Stability of the component for different amount
  of temperature is found out.

Temperature Loading
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100 ºC Temperature
Von Misces stress
Displacement
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125 ºC Temperature
Von Misces stress
Displacement
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135 ºC Temperature
Von Misces stress
Displacement
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150 ºC Temperature
Von Misces stress
Displacement
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Result Discussion

• Linear Static Analysis
• Up to 3n-4Nn of load Component is showing
  Stresses below than than the tensile strength at
  break of the used material.
• Thermal Analysis
• Used Material is having good thermal stability
  which it shows up to the 150 ºC Temperature
• Displacement is Acceptable up to the range of
  3-4mm.
• 3. Above the temperature of 150 ºC, Displacement
  is also increasing. Which is above the target
  displacement.

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Conclusion

• Composite Materials are the highly preferred
  material now a days.
• Approach for weight reduction High strength to
  weight ratio of material is considered.
• If referred steps can be molded with no fault
  then desire goal can be achieve.
• Further different more analysis like non-linear,
  impact can be performed for more accurate results.

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References-

• Modern plastics encyclopedia handbook, New York,
  McGraw-hill.
• Plastics processing handbook, Berins, Hanser
  Pub..
• Processing of composite material, B.T. Astrom
• Handbook of Enineering material, Vol.-2
  (composite), American society for materials.
• www.finitetoinfinite.com
• www.rogancorp.com
• www.moldmaster.com.
• www.ides.com

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Thank You