Presented By,

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

1.Kiran Thore2. Vikas Patil3.Vivek Kadu

Outlines:Outlines:

Introduction.Introduction.

Part Design.Part Design.

FEA Modeling.FEA Modeling.

Quality Checks.Quality Checks.

Linear Analysis.Linear Analysis.

Thermal Analysis.Thermal Analysis.

Results & Discussion.Results & Discussion.

Conclusion.Conclusion.

References.References.

Introduction:Introduction:

Composite Material:Composite Material:

“ “material consisting of more than material consisting of more than one macroscopic phase”one macroscopic phase”

matrix, disperse phase, interface

Categories:Categories:

Subdivision bySubdivision byMatrix 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

Isotropic/anisotropic

Why Composites for Cars?

Glass Fiber Composites can reduce weight by 20 -30%

Data BaseDesign MethodologiesProcessing TechnologiesMaterial Crash ModelsRapid Cure TechnologiesJoining MethodsNDTRecycling

Carbon Fiber Composites can reduce weight by 40-60%

Weight Reduction = Fuel Economy & Emission Reductions

• 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.

Automotive Light weighting Material:

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

Weight Savings and Costs for AutomotiveLight weighting Materials

Base Plate

Project Component:

Part Design:

1. Original Design.2. Modified design (features modified in the component)3. Thickness control.

Original Design:

1. Solid Model is Generated using CATIA V5 R16.

Modified Component:

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

Drafting of Modified Component:

Top View Front View Side View

Comparison between original & modified model:

Rib is Inserted

Side wall Height is increased

Wall thickness is increased

Original Model Modified model

Material Detail:Material Detail:

Required material PropertiesRequired material PropertiesHigh impact resistanceHigh impact resistance

High temperature High temperature

Dimensional stability Dimensional stability

Chemical resistance Chemical resistance

Stiffness Stiffness

Wear resistance Wear resistance

Part weightPart weight

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

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

>=250 ºC

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

Methodology & Strategy of Analysis:

Solid ModelingSolid Modeling

FEA Modeling + Quality Checks

Applying Material Properties, Boundary Conditions & Analysis

FEA Modeling:

Mesh details:1.Hypermesh 8.0 platform is used for meshing.2.FE model generated on mid surface of component.3.Mixed elements (Quad & Tria) are used for meshing.4.2D Shell elements are used (2D shells can be drawn as a line, 3D as an area.)5.Average 4.0 mm & min 2.0 mm element size is considered.6.Washer is created near holes.7.Dense meshing near hole areas.

Quality Checks:

Quality is checked on different parameters : warpage, aspect ratio, length; jacobian

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< Aspect RatioThis is the ratio of max element edge length to minimum edge length.

Ideal value = 1 (Acceptable is less than 5)

Jacobean Check >

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 lengthAverage = 4.0mmMaximum= 6.00 mmMinimum = 2.00 mm

FREE EDGES CHECKINGAny quad element having 4 free edges

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.  

 

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.

Essential B.C. Natural B.C.

Linear Analysis: Linear Analysis:

1. Analysis is performed in optistruct 8.0, package of hyper-works.2. Analysis has been carried out for different amount of loads such

as 1 N, 2 N, 3 N, 4 N, 5 N & 10 N 3. 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

2N of Load

Displacement

Von Misces stress

3 N of Load:

Displacement

Von Misces stress

4 N of load:

Displacement

Von Misces stress

5 N of Load:

Displacement

Von Misces stress

10 N of Load:

Displacement

Von Misces stress

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Thermal Analysis:

1. Thermal analysis is performed in optistruct 8.0.2. Stability of the component for different amount of temperature is

found out.

Temperature Loading

100 ºC Temperature:

Displacement

Von Misces stress

125 ºC Temperature:

Displacement

Von Misces stress

135 ºC Temperature:

Displacement

Von Misces stress

150 ºC Temperature:

Displacement

Von Misces stress

175 ºC Temperature:

Displacement

Von Misces stress

Result & Discussion:

Linear Static Analysis:1.Up to 3n-4Nn of load Component is showing Stresses below than than the tensile strength at break of the used material. Thermal Analysis:1.Used Material is having good thermal stability which it shows up to the 150 ºC Temperature

2.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.

ConclusionConclusion

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.

References:-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

Thank You…