DESIGN & DEVELOPMENT OF AIR DESIGN & DEVELOPMENT OF AIR INTAKE MANIFOLD THROUGH INTAKE MANIFOLD THROUGH

CONVERSION OF PLASTIC CONVERSION OF PLASTIC MATERIALMATERIAL

1) Rashmin Kukde.1) Rashmin Kukde.2) Ankur Koul.2) Ankur Koul.3) Ashutosh 3) Ashutosh Nandkeolyar.Nandkeolyar.4) Soumya Kumar.4) Soumya Kumar.5) Neha Gawkar5) Neha Gawkar

OUT LINEOUT LINE

INTRODUCTIONINTRODUCTIONMETAL TO PLASTIC CONVERSIONMETAL TO PLASTIC CONVERSIONMATERIAL SELECTIONMATERIAL SELECTIONMODELINGMODELINGANALYSISANALYSISRESULT AND DISCUSSIONRESULT AND DISCUSSIONMOLD FLOW ANALYSISMOLD FLOW ANALYSISCONCLUSIONCONCLUSIONREFRENACEREFRENACE

FUNCTION OF INLET FUNCTION OF INLET MANIFOLDMANIFOLD

Why metal to plastic Why metal to plastic conversionconversion

1. 1. Decrease Piece Part Prices Decrease Piece Part Prices 2. Eliminate Time-Consuming and Costly 2. Eliminate Time-Consuming and Costly

Secondary Operations Secondary Operations 3. Reduce Product Weight and Improve 3. Reduce Product Weight and Improve

User Ease User Ease 4. Gain Greater Product Structural 4. Gain Greater Product Structural

Strength Strength 5. Increase Your Product Design Options 5. Increase Your Product Design Options

Selected Material Selected Material classificationclassification

ThermoplasticsThermoplastics RecyclableRecyclable

Engineering plasticsEngineering plastics Meet the Meet the

engineering &engineering &

structural structural requirementsrequirements

NylonNylon for better for better strength &

temperature stabilities

Nylon 6,6 with Glass filledNylon 6,6 with Glass filled

Why 20% Glass filled Why 20% Glass filled Nylon 6,6?Nylon 6,6?

Thermoplastics shows up to a disadvantagewhen compare with metals. This are include:

1) Low rigidity and tensile strength,2) Dimensional instability due to a high temperature coefficient of expansion and higher water absorption.3) Low impact strength to fracture.4) Low maximum service temperature.5) Low creep resistance.6) Low hardness and scratch resistance.

Properties of Nylon 6,6 Properties of Nylon 6,6 with 20% glass fiberwith 20% glass fiber

• Melting point = 252-265°C • Maximum service temperature = 227-254°C • Thermal conductivity = 0.42 W/ mK • Co efficient of thermal expansion (at 100°C) =

336um/m°C • Specific heat = 1.8J/g°C• Density = 1.25 g/cc • Modulus of elasticity = 4.5-7.2 Gpa • Ultimate tensile strength = 120 Mpa • Yield tensile strength = 130 Mpa • Poison’s ratio = 0.33 • Hardness = R 110 • Cost = Rs180/ kg

Properties of Aluminum Properties of Aluminum casting alloycasting alloy

• Melting point = 557- 596°CMelting point = 557- 596°C• Thermal conductivity = 113W/mKThermal conductivity = 113W/mK• Co efficient of thermal expansion (at 100°C) = Co efficient of thermal expansion (at 100°C) =

22.9µm/m°C22.9µm/m°C• Specific heat =0.963 J/g°CSpecific heat =0.963 J/g°C• Density = 2.68g/ CCDensity = 2.68g/ CC• Modulus of elasticity = 71MPaModulus of elasticity = 71MPa• Ultimate tensile strength = 317MPaUltimate tensile strength = 317MPa• Yield tensile strength = 165MPaYield tensile strength = 165MPa• Poison’s ratio = 0.33Poison’s ratio = 0.33• Hardness, BHN = 75Hardness, BHN = 75• Cost = Rs135/ kgCost = Rs135/ kg

ModelingModeling For modeling a model of For modeling a model of

Inlet manifold, manufactured Inlet manifold, manufactured by Tata indica and is used by by Tata indica and is used by V2 diesel engine with V2 diesel engine with turbocharger was taken as turbocharger was taken as reference. reference.

After taking the dimensions properly a 3D graphical model is created by the use of software PRO-ENGINEER.

When I begin to create model, I went for manual measurement. In my component some holes and, some angular profiles, fillet profiles & totally the component body is like a shell like structure with taper and fillet radius and with a base part.

Picture after modelingPicture after modeling

Views of Inlet ManifoldViews of Inlet Manifold

Section Views of Inlet manifoldSection Views of Inlet manifold

Procedure of analysisProcedure of analysis

• FFor analysis of the product, the analysis software, or analysis of the product, the analysis software, HYPERMESH & ANSYS has used.HYPERMESH & ANSYS has used.

• The model is imported into HYPERMESH as an The model is imported into HYPERMESH as an IGESIGES file file format.format.

• Then midsurface for the component is created by using Then midsurface for the component is created by using midsurfacemidsurface command. command.

• Again for the midsurface geometry cleanupAgain for the midsurface geometry cleanup optionoption is used is used to make it ideal one for meshing and analysis.to make it ideal one for meshing and analysis.

• Then Then 2D mesh2D mesh for that midsurface prepared using for that midsurface prepared using automesh command by applying Manual creation and automesh command by applying Manual creation and triatria type mesh type mesh

• After finished these procedure in the HYPERMESH I try to After finished these procedure in the HYPERMESH I try to applying the applying the boundary conditionsboundary conditions for the meshed for the meshed midsurface at that time, but in my component to various midsurface at that time, but in my component to various temperature in outside and inside so I can’t apply various temperature in outside and inside so I can’t apply various temperature in single surface. So I planned to create solid temperature in single surface. So I planned to create solid mesh (3D) in the HYPERMESH. mesh (3D) in the HYPERMESH.

CAD MODEL IN CAD MODEL IN HYPERMESH PLATFORMHYPERMESH PLATFORM

Midsurface created in Midsurface created in HYPERMESHHYPERMESH

Mes MESH IN HYPERMESHMes MESH IN HYPERMESHTotal Nodes 69651

Total Elements 38034

Total Body Elements 38034

10-Node Quadratic Tetrahedron

Solid187

Boundary conditions applied: Boundary conditions applied: (Environments)in HYPERWORKS (Environments)in HYPERWORKS

WORKBENCHWORKBENCH

• Static: Static: Fixed support - Base of the Manifold which is fittedFixed support - Base of the Manifold which is fitted with Engine.with Engine. Pressure - 0.138 Mpa constant pressures inside the Pressure - 0.138 Mpa constant pressures inside the

shell.shell.

• Temperature:Temperature: Convection 1 - 120°C outside the component.Convection 1 - 120°C outside the component. Convection 2 - 30°C Inside the shell.Convection 2 - 30°C Inside the shell. Conduction - 150°C base which is fitted with theConduction - 150°C base which is fitted with the Engine.Engine.

ALUMINIUM & NYLON properties given ALUMINIUM & NYLON properties given for analysis:for analysis:

AFTER GIVING AFTER GIVING BOUNDRY CONDITIONBOUNDRY CONDITION

Results of 20% Glass filled Nylon Results of 20% Glass filled Nylon 6,66,6

(Vonmises Stress Plot)(Vonmises Stress Plot)

Results of 20% Results of 20% Glass filled Nylon 6,6 Glass filled Nylon 6,6 (Total deformation)(Total deformation)

Results of aluminum Results of aluminum alloy alloy (Total deformation) (Total deformation)

Results of 20% Glass Results of 20% Glass filled Nylon 6,6filled Nylon 6,6

(Temperature (Temperature distribution)distribution)

Results of aluminum Results of aluminum inlet manifold inlet manifold (Temperature (Temperature distribution)distribution)

Results of Equivalent Stress Results of Equivalent Stress and Total Deformation in and Total Deformation in

Aluminum Alloy.Aluminum Alloy.

•

•

• In the inlet nylon manifold the temperature distribution is very equal In the inlet nylon manifold the temperature distribution is very equal through out the body of the component and the rises in boss and fillet through out the body of the component and the rises in boss and fillet areas, but in the aluminum material the temperature distribution is not areas, but in the aluminum material the temperature distribution is not good, so the stress developed is more in aluminum. The stress good, so the stress developed is more in aluminum. The stress developed in the nylon material is with in factor of safety 3.developed in the nylon material is with in factor of safety 3.

NYLON RESULTS:NYLON RESULTS:• TOTAL DEFORMATION: TOTAL DEFORMATION: 0. m minimum0. m minimum

3.2621e-004 m maximum3.2621e-004 m maximum

• EQUIVALENT VON-MISES STRESSEQUIVALENT VON-MISES STRESS: 7.6319e-004 Pa minimum: 7.6319e-004 Pa minimum 4.9191e+007 Pa maximum4.9191e+007 Pa maximum

• MAXIMUM PRINCIPAL STRESSMAXIMUM PRINCIPAL STRESS: -1.3982e+007 Pa minimum: -1.3982e+007 Pa minimum 2.9388e+007 Pa maximum 2.9388e+007 Pa maximum

• TOTAL HEAT FLUX: TOTAL HEAT FLUX: 2.6606e-005 W/m² minimum2.6606e-005 W/m² minimum

• • TEMPERATURE:TEMPERATURE: 43.529 °C minimum 43.529 °C minimum 120. ° C 120. ° C maximum maximum

MANUFACTURING MANUFACTURING OF PARTOF PART

• The part can manufactured in two halves The part can manufactured in two halves and then with the help of ultrasonic and then with the help of ultrasonic welding we can join two parts.welding we can join two parts.

• The part can also be manufactured by The part can also be manufactured by another process that is called lost core another process that is called lost core injection molding process.injection molding process.

• I have here shows the process of I have here shows the process of manufacturing it with two halves and manufacturing it with two halves and then ultra sonic welding it.then ultra sonic welding it.

MOLD FLOW ANALYSISMOLD FLOW ANALYSIS

Material usedMaterial used

• FAMILY NAME: POLYAMIDEFAMILY NAME: POLYAMIDE• TRADE NAME: XYTELTRADE NAME: XYTEL• MANUFACTURER: DU POINTMANUFACTURER: DU POINT• FILLER: GLASSFILLER: GLASS

MESHED MODELMESHED MODEL

MESHED WITH MESHED WITH COOLING CIRCUITCOOLING CIRCUIT

PROCESS SETTINGPROCESS SETTING

PROCESS SETTINGPROCESS SETTING

PROCESS SETTINGPROCESS SETTING

FILL TIME PLOTFILL TIME PLOT

TEMPERATURE AT TEMPERATURE AT FLOW FRONTFLOW FRONT

BULK TEMPERATUREBULK TEMPERATURE

MAXIMUM PART MAXIMUM PART TEMPERATURETEMPERATURE

FROZEN LAYER FROZEN LAYER FRACTIONFRACTION

PRESSURE PLOTPRESSURE PLOT

SHEAR RATESHEAR RATE

VOLUMETRIC VOLUMETRIC SHRINKAGESHRINKAGE

TIME TO FREEZTIME TO FREEZ

SHEAR STRESSSHEAR STRESS

WELD LINEWELD LINE

OVERALL OVERALL DEFLECTIONDEFLECTION

SHOT WEIGHTSHOT WEIGHT

AIR TRAPAIR TRAP

CLAMPING FORCECLAMPING FORCE

CLAMPING FORCE AT CLAMPING FORCE AT CENTROIDCENTROID

CIRCUIT COOLANT CIRCUIT COOLANT TEMPERATURETEMPERATURE

COMPARISON OF COST & COMPARISON OF COST & WEIGHT EFFECTIVE RESULTS:WEIGHT EFFECTIVE RESULTS:

• Thus from the above results and their Thus from the above results and their comparisons it can be concluded that though the comparisons it can be concluded that though the nylon with 20% material can replace well nylon with 20% material can replace well Aluminum, then the comparison of the cost with Aluminum, then the comparison of the cost with aluminum is calculated. First we should aluminum is calculated. First we should consider the material costs of both materials: consider the material costs of both materials:

• Cost of Al casting alloy = Rs135/kgCost of Al casting alloy = Rs135/kg• Cost of Nylon 66 with 20% glass fiber = Cost of Nylon 66 with 20% glass fiber =

Rs180/kgRs180/kg• But it is Rs45 higher than that of Al casting But it is Rs45 higher than that of Al casting

alloy. But we think the density of them it is alloy. But we think the density of them it is found that,found that,– Density of Al casting alloy (2.68gm/cc) Density of Al casting alloy (2.68gm/cc) – Density of Nylon6,6 with 30% glass fiber (1.35gm/cc)Density of Nylon6,6 with 30% glass fiber (1.35gm/cc)

ConclusionConclusion The entire project on “DESIGN &

DEVELOPMENT OF AIR INTAKE MANIFOLD THROUGH CONVERSIONOF PLASTIC

MATERIAL” in the sense of metal to plastic conversion has been completed with full

concentration as far as possible regarding the modeling and analysis.

Thus after the project is over, it can be concluded that by a slight modification of the

design and through a proper process design the material of the Inlet Manifold can be converted into Nylon 6,6 with 20% glass fiber successfully

with a reduced cost for the same or better performance.

REFERANCEREFERANCE

• Modern Plastics Encyclopedia handbook (1994) Modern Plastics Encyclopedia handbook (1994) New York, McGraw-hill.New York, McGraw-hill.

• Smith, M.A(1986) in the Wiley encyclopedia of Smith, M.A(1986) in the Wiley encyclopedia of packaging technology, M. Bakker (Ed),New packaging technology, M. Bakker (Ed),New York, John Wiley & Sons.York, John Wiley & Sons.

• Susan E.M. Selke “Understanding Plastics Susan E.M. Selke “Understanding Plastics Packaging Technology” Hanser publisher, Packaging Technology” Hanser publisher, Munich.Munich.

• Michel L.Berins, “Plastics Engineering Michel L.Berins, “Plastics Engineering Handbook of the society of plastics industry, Handbook of the society of plastics industry, inc. fifth edition.inc. fifth edition.

• P.Radhakrishnan, C.P.Kothandaraman, P.Radhakrishnan, C.P.Kothandaraman, “Computer graphics & design”, Danpat rai “Computer graphics & design”, Danpat rai publications , New Delhi, 2000.publications , New Delhi, 2000.

REFERANCEREFERANCE

• Sidney Levy, J.Harry Dubois, “Plastics Product Sidney Levy, J.Harry Dubois, “Plastics Product Design Engineering Handbook”, Van Nostrand Design Engineering Handbook”, Van Nostrand Reinhold Company, Sidney.Reinhold Company, Sidney.

• Ronald D. Beck, “Plastics Product design”, Yan Ronald D. Beck, “Plastics Product design”, Yan Noastrand Reinhold Company, London.Noastrand Reinhold Company, London.

• R.G.W. Pye, “Injection mould design for R.G.W. Pye, “Injection mould design for thermoplastics, Affiliater east-west Press P.Ltd, thermoplastics, Affiliater east-west Press P.Ltd, New Delhi, 1989.New Delhi, 1989.

• Irvin Rubin, Injection Molding Thery and Irvin Rubin, Injection Molding Thery and practice, A.Wiley Interscience Publications, 1972.practice, A.Wiley Interscience Publications, 1972.

• Donald V. Rosato, Injection molding handbook, Donald V. Rosato, Injection molding handbook, International Thomsan Publishing company, International Thomsan Publishing company, 1985.1985.