Design and analysis of turbo charger

ABSTRACT

In these days of technological advancements in Automobile sector where

mans penchant is to develop technologies that can improve the power and
mileage of the vehicle TURBOCHARGER is one such exotic gadget.

Any engine needs air for combustion of fuel and it is the Air-Fuel ratio the
decides the performance of an engine. Hence supply of air is an important
task. During high speed operation of any engine there is not enough time for
air to be sucked in the cylinder by itself (by the creation of vacuum during
suction stroke).Hence the volumetric efficiency goes on decreasing as engine
picks up speed as a result of which only partial combustion takes place. To
fulfill the deficiency of air supercharging and consequently turbocharging
came into picture.

A TURBO CHARGER is basically an exhaust gas driven air compressor which

compresses the ambient air and sent this pre compressed (optionally
Intercooled) air into the cylinder during suction stroke. It consists of two
basic parts, the exhaust gas driven turbine and its housing, and the air
compressor and its housing. The exhaust air from the engine spins the
turbine and leaves while the compressor wheel, connected to the common
shaft of turbine and compressor, compresses the ambient air and feeds it to
the engine.

Modern turbochargers are complex assemblies of various accessories

attached to it like wastegate, blow off valves, oil and water plumbing, ECU
with sensors, Pressure gauges etc.

Since the turbine spins at exceptionally very high speeds of the order of 1-2
Lac rotations per minute it has to designed carefully taking various
parameters into considerations. Also as it is continuously subjected to very
high exhaust gas temperature of the order of 600-900 degree centigrade
thermal strength also plays important role. Turbine of the turbocharger also
has to resist the high pressure of the exhaust gas at elevated temperatures.

Hence in our project we have incorporated the two major design

considerations of turbine of Turbocharger:
 • Structural Aspects.

• Thermal Aspects.

Modeling and Analysis of the turbine wheel of a turbocharger is presented in

our project. For modeling we have used the real time modeling package
ProEngineer WF 3.0 and for analysis we have used the prevalent FEM
analysis package ANSYS 10.

Our Analysis includes both Structural and Thermal Analysis of the turbine
wheel.

Special focus on the results part has been given in order to help designers.
Various contour plots has been studied and presented so as to acquire
proper idea about the deflections and stress distributions on the turbine
blade.

In case of thermal Analysis, Nodal temperatures and the distribution of the

temperature across the turbine blade has been obtained and explained.

Another interesting part of our project is the “EXTENSION OF

TURBOCHARGING TO TWO WHEELERS”

We have presented the possibilities of turbocharging a two wheeler which

has not been done yet in commercial vehicles till date.

Turbocharging a two wheeler has many potential like power boost, Mileage
improvement etc which can be achieved easily by installing a turbocharger.

We have presented the advantages and limitations of this concept.

Tittle: Design and buckling analysis of two post Screw auto lifter.

ABSTRACT:
 A good automobile shop must have equipment to undertake all types of fault
finding and servicing jobs. The tools and equipment which are must in the auto shop
are namely screw drivers, spanners, hydraulic lift, wheel balancing equipment etc.
One of the important equipments is the hydraulic lift which can be a 2-post, 4-post,
6-post which is used to lift the vehicles to a comfortable height in order to work
under it. For the same purpose the latest equipment used is the Screw Auto Lift.

Much of the fatigue damage in the tools and equipments of a auto shop can be
limited to the compressive forces acting on them. Buckling under axial load is one
of the most common failures which appear before crushing. This project is about
“Buckling Analysis on a two post Screw auto lift”. The compression members, whom
we come across, do not fail entirely by crushing. These members, which are
considerably long when compared with their lateral dimensions start bending, i.e.
buckling. When the axial load reaches a certain critical value, and screw auto lift is
one such member. Both experimental and analytical work has been performed on a
screw auto lift; employing commercial ansys program, based on the finite element
method on a 3d solid model developed in pro/e.

The possible use of alloy steels(nickel steels) in place of mild steel has got
improved properties like increase in the strength and the elastic limit of the alloy
.The results suggest that use of the nickel steels improves the properties such as
strength, ductility, and corrosion resistance over the specifications of the two post
screw auto lift. .It also increases the durability of the equipment, two post screw
auto lift.

Project 2:
Tittle : Design and analysis of spindle with Spm (special purpose
machine).

ABSTRACT
The present work is carried out on TWO STATION TWO SPINDLE CAM BORE
ROUGHING /FINISHING SPM.It is a SPECIAL PURPOSE MACHINE exclusively used for
HEROHONDA in which it is used for fine boring to reduce the oil consumption of the
two wheeler.

The objective of my project is to generate a parametric assembly

drawing of spindle assembly using Pro-E, and analysis of spindle assembly using
ANSYS.

Firstly, we created a solid model of the crankshaft using designing

software

“Pro-e”. Then the model is imported into Ansys and analyzed by applying necessary
conditions, which were considered in designing it and then checked for the strength
and life. The specifications required for the design are taken from the drafted
design

The analysis of spindle assembly includes:

• Analysis of spindle deflection due to tensioning of belt

• Spindle analysis for deflection due to axial and radial forces
• Based on deflection decide an optimum positioning of the spindle bearings

. Project 3:
Tittle: Structural analysis of six wheeler chassis.

ABSTRACT

The present scenario in automotive industry is an increase in demand of trucks not only on the
cost and weight aspects but also on improved complete vehicle features and overall work
performance. The chassis plays an important role in the design of any truck.

The chassis design in general is a complex methodology and to arrive at a solution which yields
a good performance is a tedious task. Since the chassis has a complex geometry and loading
patterns, there is no well defined analytical procedure to analyze the chassis. So the numerical
method of analysis is adopted, in which ‘Finite Element Technique’ is most widely used method.

The main objective of this work is to evaluate static characteristics of a truck chassis under
different load conditions. Geometric modeling of the various components of chassis has been
carried out in part mode as 3-D models using PRO-ENGINEER. The properties, viz.
crossectional area, beam height, area moments of inertia of these 3-D modeled parts are
estimated in PRO-ENGINEER. These properties have been used as input while performing the
Finite Element Analysis using ANSYS work bench.

Project 4:

Tittle: Design and analysis of connecting rod 4s S.I engine.

ABSTRACT

Connecting rod is a structural member in the engine, which transfers

reciprocating motion into rotary motion of crank shaft

The connecting rod while transferring the power from piston to crank shaft takes
load from piston due to combustion process in the combustion chamber

The load acts at a particular crank angle to the max hence the connecting rod is
analyzed due to stress developed, due to load conditions and changes mentioned

In this analysis a model of connecting rod is generated in pro/e and analyzed in

ansys using FEM (finite element method) by applying loads and boundary
conditions, and then solved for engineering responses.
Project 5:

Tittle: Design and analysis of crank shaft 4s S.I engine.

ABSTRACT

In this project we designed and analyzed a crankshaft of 4-stroke S.I engine using
“Ansys”, which is software, which works on the basis of finite element method.

Firstly, we created a solid model of the crankshaft using designing software

“PRO/E”. Then the model is imported into Ansys and analyzed by applying
necessary conditions, which were considered in designing it and then checked for
the strength and life. The specifications required for the design are taken from the
drafted design.

The results were found in the analysis of the crankshaft, the design is found out to
produce more stresses and some modifications were done to the design and again it
is analyzed and the stresses developed were lesser when compared to the previous
design.

The engine, which is used, is a four-stroke S.I engine. It is a twin cylinder

multi utility engine. It is a horizontal shaft engine. The cylinder volume of the engine
is 196cc and it is used in cold countries for snow cutting purpose. It is also used for
grass cutting.
Project 6:

Tittle: Structural and thermal analysis of gas turbine casing

ABSTRACT

Gas Turbine is a rotary engine, which converts the energy of hot gases into mechanical energy.
The hot flue gasses at high pressure and high temperature expand in the turbine section to
produce mechanical work. Turbine casing (shell) controls the axial and radial positions of
the shrouds and nozzles.
It determines Turbine clearances and relative positions of the nozzles to the Turbine buckets.
This positioning is critical to Gas Turbine performance.

The main objective of the present investigation is to analyze the temperature distribution,
stresses developed throughout the casing by using FEM. In this project thermal analysis
at steady state, thermal and structural analysis and optimization of casing are carried out.
Thermal and structural analysis on casing is carried out with increased gas temperatures
than the existing operating conditions.

Project 7:

Tittle: Design and analysis of piston 4s S.I engine.

ABSTRACT
The project “DESIGN AND ANALYSIS OF 4-STROKE S.I. ENGINE PISTON” is
about designing the piston according to the forces acting on it from the gases,
which are released during the combustion.

The piston head acts as a particular case and hence the piston is analyzed for the
stresses developed due to the conditions.

At first, the piston is designed according to the specifications. After the designing,
the model is subjected to certain conditions. According to the conditions we have
checked the stresses acting on it and checked the failures of the model. After the
analyzing the changes are done to the model if required.

In the analysis a model of piston is generated using Pro/E. the finite element model
of the piston is generated using Ansys. It is applied with loads and boundary
conditions. Thus solved for the engine response.

The result are calculated and tabulated below and the stresses acting on the
body are shown.

Project 8:

Tittle: OPTIMIZATION & ANALYSIS OF RICE MILL ROLLER.

ABSTRACT

The rollers used in rice mill are also called as friction rollers. The use of these rollers is to
remove the husk from the rice. In practice, there will be two rollers which rotate in opposite
direction. The paddy flows between these rollers and separates the husk and rice. During this
separation a high amount of the friction is induced in these rollers. Due to this friction the rollers
have a chance of breakage at exactly the center of the roller. The maximum life of these rollers is
not more than two to seven days.

The present work is carried out to overcome these problems. We approach the problems in
two ways to increase the life of the rollers and strength of the rollers. Since these rollers
have a circular cross section and more number of boundary conditions, which analytical methods
fail to analyze. Hence, we employed numerical methods which provide an approximate, but
acceptable solution. Finite Element Method technique is applied for boundary value problems
and it is integrated with high speed digital computer and to analyze complex domain with
relative ease.

For this analysis component is modeled in PRO/E, which is then imported to

HYPERMESH for attaining the pre- processing and then it is exported to ANSYS for analyzing
structural, linear and rotational stress analysis.

Project 9:

Tittle: ACTIVE TWIST OF MODEL ROTAR BLADES WITH D-SPAR

DESIGN.

ABSTRACT

The design methodology based on the planning of experiments and

response surface technique has been developed for an optimum placement of
macro fiber composite (MFC) actuators in the helicopter rotor blades. The baseline
helicopter rotor blade consist of D-spar made of UD GFRP, skin made of +45/-45
GFRP, foam core, MFC actuators placement on the skin and balance weight. 3D
finite element model of the rotor blade has been built by ANSYS, where the blade
skin and spar “moustaches” are modeled by the linear layered structural shell
elements SHELL63, and the spar and foam –by 3D 20-node structural solid elements
SOLID 45. The thermal analyses of 3D finite element model have been developed to
investigate an active twist of the helicopter rotor blade. Strain analogy between
piezoelectric strains and thermally induced strains and thermally induced strains is
used to model piezoelectric effects. The optimization results have been obtained for
design solutions, connected with the application of active materials, and checked by
the finite element calculations.

Project10.

Tittle: DESIGN AND ANALYSIS OF A COMPOSITE BEAM FOR SIDE IMPACT

PROTECTION OF A SEDAN .

ABSTRACT

Side Impact crashes can be generally dangerous because there is no room for
large deformation to protect an occupant from the crash forces. The side impact
collision is the second largest cause of death in United States after frontal crash.
Day by day increase in the fuel cost and the emission of the smoke from the
automobile industry are also the major concerns in the contemporary world, hence
the safety, fuel efficiency and emission gas regulation of the passenger cars are
important issues in contemporary world. The best way to increase the fuel efficiency
without sacrificing the safety is to employ composite materials in the body of the
cars because the composite materials have higher specific strength than those of
steel. Increase in the usage of composite material directly influences the decrease
in the total weight of car and gas emission. In this research, Carbon/Epoxy
AS4/3051 -6 is used as material for side impact beam which has adequate load
carrying capacities and that it absorbs more strain energy than steel.

The Finite Element models of a Ford Taurus car and the Moving Deformable
barrier (MDB) as developed by National Crash Analysis Center (NCAC) have been
utilized for the analysis in this thesis. The current side impact beam is removed
from the car and the new beam which is developed using CATIA and MSC.Patran is
merged on to the driver side of the front door of the car model.

The total energy absorption of the new beam with steel and composite
material is compared with the current beam. The intrusion of the beam is evaluated
by using FMVSS 214 and IIHS side impact safety methods. The new impact beam
with composite has high impact energy absorption capability when compared to
current beam and new beam with steel, with 65% reduction in weight.

Project 11.

Tittle: An Experimental Study on the Vibration Characteristics of the Rotor Blade

with Fiber Reinforced Plastics .

ABSTRACT:

With the current background of increasing oil price, a number of researches on development and
supply of renewable energy are on process. Wind energy is one of them. Not only as energy
itself, but also as travel resources, windenergy is ideal substitute for Korea equipped with
appropriate conditions.
The purpose of this paper is that investigates the dynamic behavior characteristic of W.T.S
(Wind Turbine System) andcarries out the evaluation analysis during operating W.T.S. To
investigate the dynamic behavior characteristic of W.T.S,the experiments to measure vibration of
the blade from the attached accelerometer on the flap and edge section of the bladethat is one of
the most important elements of dynamic characteristic of W.T.S are performed. Natural
frequency and modeshape are calculated with commercial program (ANSYS) using the
measured vibration acceleration that receives the signalwith F.F.T Analyzer from the
accelerometer. For validation of these experiments, the finite element analysis is performedwith
commercial F.E.M program (ANSYS) on thebasis of the natural frequency and mode shape. The
results indicate thatexperimental values have good agreements with the finite element analysis.
Tittle:
STRESS ANALYSIS OF AIRCRAFT METAL FUEL TANK UNDER
FEDERAL AVIATION REGULATIONS –PART 23”
ABSTRACT

NAL is in the process of developing HANSA – 4 Aircraft, which is ideally suited

for civil transport, aerial survey, training etc. This HANSA is designed according to
Federal Aviation Regulations Part 23 (FAR-23) design document. This is a guideline
for design of aircraft having a maximum takeoff weight of more than 750 kg and up
to 19500 kg. The FAR-23 design document details out the loads and broad
procedures for design of aircraft components like fuel tank etc.

The fuel tank designed for HANSA – 4 is made of Aluminum alloy and it can
carry 100 liters of Aviation petrol having specific gravity of 0.73. In this work, stress
analysis of this fuel tank under FAR loads is considered for different inertia load
cases, in addition to static test pressure of 3.5 psi. (24 KPa).

Finite Element Analysis is carried out to arrive at stresses and displacements

in critical components. The Analysis is carried out using ansys software finally, from
the results it is concluded that the structure is safe and has adequate margin of
safety in critical components of fuel tank.

Project 15

Tittle:
MODELING AND ANALYSIS OF MOUNTING PLATE OF A ROTARY
COMPRESSOR

ABSTRACT

In the Tecumseh Compressors, the compressors manufactured are using

mounting plates having the pitch circle diameter of 211mm. This mounting plate is
welded to the compressor bottom and through the holes of this plate; the
compressor gets mounted on to the A/C housing.

The vibrations from the compressor get transferred to the A/C housing there
by producing noise, which is undesirable. These vibrations will be greater enough to
produce noise when the natural frequencies of the compressor, the mounting plate
and the A/C housing coincide resulting in resonance. To avoid this, there should be
a frequency shift in either of the components. Frequency shift in Mounting Plate will
give better results as that is the media of transfer of Vibrations form compressor to
the A/C housing.

Under this Project, determination of the Natural frequencies of the mounting

plate, amplitudes of vibration in it are studied. This determination is done using
Static, Modal and Harmonic Analyses. Three models have been considered and on
the existing model experiments have been carried out. The analysis results of the
existing model are compared with the experimental results and validating the
analysis procedure, the same analyses are carried out to the rest of the two models.
Upon analysis of the three models, the better one out of them is suggested.

Project 16

Tittle:
DESIGN AND ANALYSIS OF INJECTION MOULD FOR MINERAL WATER
BOTTLE CAP

ABSTRACT

Injection molding is the most important process in the manufacturing of

plastic parts. It is done by forcing melted plastic in to a mold cavity until it cools and
forms a specific plastic shape. Plastic injection molding is very useful when the
plastic parts that need to be produced are too complex or expensive to do by
machine. With plastic injection molding, many parts can be made simultaneously
(using the same mold).

The plastics used are the thermo-plastic (hdpe) as these materials soften
when heated and re-harden when cooled. No chemical changes take place when the
material is heated or cooled, the change being entirely physical. For this reason, the
softening and re-hardening cycle can be repeated any number of times.

In this work, stress analysis of this cap cavity plate under the pressure 40
2
N/mm is considered, in addition to this thermal analysis is carried out at injection
temperature 2200C and mold temperature 200C.
 Cap is modeled in PRO-E and the meshing part is done in HYPER MESH 7.0
and analysis is carried out in ANYSIS 10.0. A finite element analysis is carried out to
arrive at stresses, and deformation in cap cavity plate. Finally, from the results it is
concluded that the structure is safe and has adequate safety in component of cap
assembly.

Project 17

Tittle:
DESIGN AND ANALYSIS OF AUTOMOTIVE TRUCK CAB SUSPENSION
SYSTEM

ABSTRACT

The suspension system is used to isolate the chassis from the shock loads
due to irregularities of the road surface. This must be handled without impairing the
stability, steering or general handling of the vehicle. Suspension system for the cab
is placed between the bottom of the truck cabin floor and chassis. The suspension
system is fitted to the chassis using bolts. The loads coming from the floor and the
chassis are taken by the suspension system to reduce the shocks levels to the
driver in the cabin.

The model is designed in Catia V5 and meshed in Hypermesh7.0 and

translated to Ansys 10.0. The model is simplified in Ansys by using the
preprocessor. Constraint equations and couples are used to connect various regions
of the suspension system. The loads are applied on the top flange of the suspension
system.

Static analysis is made to study the deflection of the suspension system.

Modal analysis is made to check the natural frequencies. Harmonic analysis is also
done to plot various graphs between frequency and amplitude. Results and
discussions are made from the results obtained from the Ansys and conclusions are
given and scope for future work is also given.
Project 18

Tittle: DESIGN AND ANALYSIS OF TILTABLE TRUCK CABIN FLOOR

ABSTRACT

In the truck the floor as a load gatherer and takes the loads of the driver and
co-driver loads and also the side loads and the road loads under different loading
conditions. The loads from the road are transmitted to the floor through the vehicle
suspension to the cabin suspension and the n to the floor

Floor is modeled in CATIA and the meshing part is done in HYPER MESH 7.0
and analysis is carried out in ANYSIS 10.0. A finite element analysis is carried out to
arrive at stresses and deformation on the floor. Finally, from the results it is
concluded that the structure is safe and has adequate safety.

Project 19

Tittle:
ANALYSIS OF RESIDUAL STRESSES IN A BUTT WELD USING ANSYS
SOFTWARE

ABSTRACT

Low carbon steels are prone to distortion and cracks due to residual stresses
induced during welding. This project gives the information about the residual
stresses induced in a butt weld joint due to welding. Experimentation was carried
out on a plate made of low carbon steel having dimensions 0.115 x 0.048 x 0.006
meters. The type of welding chosen is Manual Metal Arc Welding (MMAW). Single
pass welding was carried out. Experimental values calculated were taken as input
for the analysis in ANSYS software.
 A model was generated in ANSYS 9.0 (A general purpose FEA software) using
SOLID BRICK 8 NODE 70 (3D solid element with temperature dof) and PLANE 55 (A
2D Solid Element with 4 nodes), as per the dimensions of the plate taken for the
experimentation. A refined mesh is made based on the convergence criteria and the
analysis is performed to estimate the temperature distribution. Firstly a transient
thermal analysis was carried out by giving heat flux as the time varying input to
estimate the temperature variation. The non-linear material properties are fed for
the heat transfer solution. Then coupled field analysis is carried out to get the
residual stresses by coupling thermal analysis to static analysis. The variation of the
temperature with time, and residual stresses are obtained. The variation of these
are reported and discussed.

Project 20

Tittle:
DELAMINATION STUDIES IN FRP COMPOSITES USING 3D FINITE
ELEMENT ANALYSIS

ABSTRACT

FRP laminated composites have been extensively used in Aerospace and

allied industries due to their inherent advantages over conventional materials.
However these are also susceptible to damages especially under transverse
loading. Failure modes of such laminated structures are different than those of
conventional metallic materials. One important and unique mode of failure in such
components is Delamination. Delamination is separation of adjacent plies/laminae
due to existence of interlaminar stresses. This mainly occurs at free edges or
around discontinuities depending upon the stacking sequence of the laminate. Once
Delamination occurs, it becomes important to know whether the laminate could still
be used with the existing delamination or up to what size of the Delamination the
laminate could be used. So the present work aims at analyzing a laminate having
Delamination to determine the severity of the existing Delamination and the
propensity of the Delamination growth. 3DFE analysis along with concept of LEFM
will be used the FRP laminated composites.

Project 21

Tittle:
DESIGN AND STRUCTURAL ANALYSIS OF HIGH SPEED HELICAL GEAR
USING ANSYS
ABSTRACT

Marine engines are among heavy-duty machineries, which need to be taken care
of in the best way during prototype development stages. These engines are
operated at very high speeds which induce large stresses and deflections in the
gears as well as in other rotating components. For the safe functioning of the
engine, these stresses and deflections have to be minimized.

In this project, static-structural analysis on a high speed helical gear used in

marine engines, have been performed. The dimensions of the model have been
arrived at by theoretical methods. The stresses generated and the deflections of the
tooth have been analyzed for different materials. Finally the results obtained by
theoretical analysis and Finite Element Analysis are compared to check the
correctness. A conclusion has been arrived on the material which is best suited for
the marine engines based on the results.

Project 22

Tittle: DYNAMIC ANALYSIS OF THIN –WALLED COMPOSITE I- BEAMS

ABSTRACT

In an effort to save weight while still remaining high strength, many

contemporary structural systems are designed with lower margins of safety than
predecessors. The criterion of minimum weight design is particularly prevalent in
the design of aircraft, missile, and spacecraft vehicles. One obvious means of
obtaining a high strength, minimum weight design is the use of light, thin-walled
structural members of high strength alloys. Thin- walled beams of open sections
such as I, Z, Channel and angle sections are frequently used for intricate structures
in spacecrafts. Due to low torsional rigidity thin-walled beams of open sections, the
problem of torsional vibrations and stability is of prime interest. For the last three to
four decades mechanical vibrations have been recognized as a major factor in the
design. Mechanical vibrations produce increased stress, energy loss and noise that
should be considered in the design stages if these undesirable effects are to be
avoided, or to be kept minimum.
 The present work particularly deals with dynamic analysis of lengthy
uniform thin-walled uniform I-beams and tapered I-beams of open sections,
particularly composite beams. Fiber-reinforced plastics (FRP) have been increasingly
used over the past few decades in a variety of structures that require high ratio of
stiffness and strength to weight. In the present thesis, the analytical model
developed by Lee and Kim [11] is taken and the dynamic behavior of a thin-walled I-
section composite beam is studied in detail. This model accounts for the coupling of
flexural and torsional modes for arbitrary laminate stacking sequence configuration,
i.e. symmetric as well as unsymmetric, and various boundary conditions are also
discussed in detail. A displacement-based one-dimensional finite element model is
developed to predict natural frequencies and corresponding vibration modes for a
thin-walled composite beam. Equations of motion are derived from Hamilton's
principle. Numerical results are obtained for thin-walled composite beams
addressing the effects of fiber angle, modulus ratio, height-to-thickness ratio, and
boundary conditions on the vibration frequencies and mode shapes of the
composites. Using ANSYS 10.0, the modal and harmonic analysis are carried out
and presented in graphical form.

Project 23

Tittle:DYNAMIC RESPONSE ANALYSIS OF A THREE WHEELER CHASSIS

FRAME USING FINITE ELEMENT ANALYSIS

ABSTRACT

A three-wheeler is essentially a motion disturbance vibrating system with the

ground providing input. The tyres which are in contact with the ground, convert this
input displacement into a forcing function which acts on the unsprung masses,
these masses are constrained by linkages so that they follow certain paths. Ride
response is dependent on the ground profile, tyre and suspension characteristics,
physical dimensions and the inertial properties of the sprung and unsprung masses
of the vehicle.

The objective of this thesis is to analyze the dynamic behavior of vehicle

using Finite Element modeling. This project also includes the response of the three
wheeler chassis frame to road surface inputs and to provide the best vehicle in
vibratory motions.
 In Finite element modeling, analysis is done to determine the dynamic
behavior of the vehicle in Harmonic and Transient excitations. Modal analysis and
parametric study has also been carried out. Spectrum analysis is carried out in
order to obtain the maximum stresses, as the vehicle running on the road is
subjected to the random vibrations.

The results obtained from Finite element modeling in modal analysis were
studied and are compared with those of rigid body modeling. In Transient analysis
excitation magnitude and acceleration values at the key nodes are analyzed. From
spectrum analysis maximum stress point is noted. Conclusions were derived from
the study and suggestions are made to improve the performance of vehicle, thus
stability is established.

Project 24

Tittle: FINITE ELEMENT ANALYSIS OF LPG CYLINDER

ABSTRACT

This project aims at reduction of weight of Liquid petroleum gas (LPG). So,
the finite element analysis of Liquefied Petroleum Gas (LPG) cylinders made of Steel
and Fiber Reinforced Plastic (FRP) composites has been carried out. Finite element
analysis of composite cylinder subjected to internal pressure is performed. Layered
shell element of a versatile FE analysis package ANSYS (version 9.0) has been used
to model the shell with FRP composites.

A number of cases are considered to study the stresses and deformations

due to pressure loading inside the cylinder. First, the results of stresses and
deformation for steel cylinders are compared with the analytical solution available
in literature in order to validate the model and the software. The weight savings are
also presented for steel, Glass Fiber Reinforced Plastic (GFRP) composites and
Carbon Fiber Reinforced Plastic (CFRP) composite LPG cylinders. Variations of
stresses and deformations throughout the cylinder made of steel, GFRP and CFRP
are studied.
 A complex orthotropic mechanics of FRP composites has been studied and
discussed in brief to have some understanding of behavior of FRP composites. In
addition to that an introductory Finite Element Method has also been presented on
the basis of which the cylinder has been analyzed.

Project 25

Tittle: FINITE ELEMENT ANALYSIS AND FATIGUE ANALYSIS OF SPUR GEAR

UNDER RANDOM LOADING

ABSTRACT

The gear fitted in the gearbox Armored tracked vehicle is vulnerable to

considerable fatigue damage over its life period due to the dynamic excitations
caused by the terrain undulations, the rotating wheel and track assemblies. For this
purpose, initially static analysis of the model was carried out to validate the model
and the boundary conditions correctness. Further Modal analysis is carried out to
determine the dynamic characteristics of the gear model. The random load time
history is transformed in to frequency domain using Fast Fourier transform to obtain
load power spectral density (PSD). Then the stress PSD response is obtained at
critical node from the random vibration analysis. Once the spectrum of stress
variation is obtained given input to the fatigue analysis and fatigue life is
determined by FE package ANSYS 9.0.

Project 26

Tittle: FINITE ELEMENT ANALYSIS OF A GAS TURBINE ROTOR BLADE

ABSTRACT

In the present work the first stage rotor blade of a two-stage gas turbine has
been analyzed for structural, thermal using ANSYS 9.0, which is a powerful Finite
Element Software. In the process of getting the thermal stresses, the temperature
distribution in the rotor blade has been evaluated using this software.

The design features of the turbine segment of the gas turbine have been
taken from the preliminary design of a power turbine for maximization of an
existing turbojet engine. It was observed that in the above design, the rotor blades
after being designed were analyzed only for the mechanical stresses but no
evaluation of thermal stress was carried out. As the temperature has a significant
effect on the overall stress on the rotor blades, it has been felt that a detail study
can be carried out on the temperature effects to have a clear understanding of the
combined mechanical and thermal stresses.

In the present work, the first stage rotor blade of the gas turbine has been
analyzed using ANSYS 9.0 for the mechanical and radial elongations resulting from
the tangential, axial and centrifugal forces. The gas forces namely tangential, axial
were determined by constructing velocity triangles at inlet and exist of rotor blades.
The rotor blade was then analyzed using ANSYS 9.0 for the temperature
distribution. For obtaining temperature distribution, the convective heat transfer
coefficients on the blade surface exposed to the gas have to feed to the software.
The convective heat transfer coefficients were calculated using the heat transfer
empirical relations taken from the heat transfer design dada book. After containing
the temperature distribution, the rotor blade was then analyzed using ANSYS 9.0 for
the combined mechanical and thermal stresses. The radial elongations in the blade
were also evaluated.

The material of the blade was specified as N155 but its properties were not
given. This material is an iron based super alloy and structural and thermal
properties at gas room and room temperatures were taken from the design data
books that were available in the library of BHEL(R & D), Hyderabad.

The turbine blade along with the groove is considered for the static, thermal,
modal analysis. The blade is modeled with the 3D-Solid Brick element. The
geometric model of the blade profile is generated with splines and extruded to get a
solid model.

The first stage rotor blade of a two-stage gas turbine has been analyzed for
structural, thermal using ANSYS 9.0 Finite Element Analysis software. The thermal
boundary conditions such as convection and operating temperatures on the rotor
blade are applied on theoretical modeling. Analytical approach is used to estimate
the tangential, radial and centrifugal forces

Project 27
.

Tittle: FINITE ELEMENT MODELING AND STATIC ANALYSIS OF OPEN

TOWER

ABSTRACT
 Open towers are one among the different types of towers used for the
purpose of signal transmission. They are telescopic in nature and are designed in a
special manner, which makes the whole structure portable by converting in to a
single unit. It consists of main pipe and four supporting members. In order to reduce
the weight of the structure it is fabricated with fiber reinforced plastics (FRP). The
main pipe is a combination of several sections, which slide into the main member
with the help of rollers to form a single unit. The four supporting members can be
made integral with the main pipe with the help of a movable flange which slides on
the main member.

Finite element modeling of the tower is created in HYPER MESH 07. The
analysis is carried out in ANSYS 09. The boundary conditions considered here are
wind pressure and top plate weight. The wind pressure is calculated considering
velocity of the wind as 90 kmph based on geographical and geothermal factors.
This wind pressure is applied as a horizontal force and a moment force at the top of
the pipe. The tower analysis is carried out with shell and brick elements. Mesh is
created with shell 99 and solid 95. Rod elements are used wherever the direct
contact between the surfaces is not there. The maximum displacement occurred at
the top and the maximum stress induced in between the layers are calculated and
observed that they are in allowable limits. By this analysis the design of tower is
safe based on rigidity criteria and strength criteria.

Project 28

Tittle: LINEAR AND NON-LINEAR ANALYSIS OF ROTATING GASTURBINE

WHEEL CONSIDERING HOTSPINNING

ABSTRACT

A Turbine wheel forms significant part of gas turbine. It forms a connecting

media between the blades and the shaft. The blades due to the exhaust gases from
the combustion chamber are set into rotating motion. The rotor on which the blades
are mounted transmitting this motion holds a key point to better efficiency of gas
turbine as a whole unit. Thus more focus should be given to the design of the
turbine rotor.
 Hot spinning operation involves mainly the spinning of the turbine wheel at a
speed of 1.5 times the operating speed and at a temperature slightly more than
ambient. As a result stresses are produced which are more than the yield stress
which enter into the plastic range, producing a strain outward from the axis. Now,
when the turbine wheel is brought back to zero speed some amount of residual
stresses are stored in the turbine wheel. When the turbine wheel runs under
operating conditions the strain produced should first overcome the residual strain
developed towards the center which reduces the actual stresses.

The stress analysis of the turbine wheel is done by using finite Element
Method. This FEM analysis is done by using ANSYS. Firstly, a linear analysis is done
by applying the thermal stresses at operating conditions. These stresses obtained
are without hot spinning. The residual stresses are calculated by using the
nonlinear analysis. Now, these residual stresses are superimposed on the thermal
stresses at operating conditions after hot spinning which are much less than the
linear stresses calculated without hot spinning.

Project 29

Tittle: SEISMIC AND WIND LOAD ANALYSIS OF SURGE TANK

ABSTRACT

This project is Deals with seismic and wind load analysis of surge tank

The purpose of tank is to limit the number hour’s starts of the pumps placing
parts of its stock of water which is maintained under pressure by the air above it at
the disposal of the system.

The surge tank can be of the air cushion or diaphragm type. In the air cushion
version there is no clear separation between air water since part of the air tends to
mix with water it is necessary to restore it by means of air supply units or
compressor.
 In the diaphragm version neither air supply units nor compressor are needed
as contact between air and water prevented by a flexible diaphragm inside the
tank.

The following method which is used to determine the volume of surge tank is
valid both for horizontal and vertical surge tanks. When calculating the volume of
the surge tank it is generally sufficient to consider the first pump only.

In the present work the analysis of surge tank is carried out for:

• WIND LOADS

• GRAVITY LOADS

• SEISMIC LOADS

Project 30

Tittle:
STABILITY ANALYSIS OF STEEL AND COMPOSITE RAILROAD TIES
USING FEM

ABSTRACT

A railroad tie, cross tie, or sleeper is a rectangular object used as a base for
railroad tracks. Traditionally, ties have been made of wood, later steel has also
been used and concrete is now widely used along with composite materials. To
determine the various stresses in the ties due to static and dynamic loads, the
finite element method is used which is accurate and time saving. The FEM has
developed simultaneously with the increasing use of high speed electronic digital
computers and with the growing emphasis on numerical methods for engineering
analysis. The systematic generality of the finite element procedure makes it a
powerful and versatile tool for a wide range of problems. In this project, the finite
element analysis software such as ANSYS R11.0 is used to carry out the stress
analysis.

In this work, 3D analysis is used to carry out a railroad tie made of steel and
composite materials under static and dynamic loads. A detailed model of the tie is
created using ANSYS geometric modeling options. Due to static loading the stress
distributions and deflections are investigated. The plots of distribution of stress is
depicted with the results and their influence on the tie is discussed. Further modal,
harmonic and transient analysis is performed to obtain dynamic stability.The
analysis suggests that composite ties can be used instead of steel ties and stress in
the ties can further be reduced by increasing the thickness of composite ties and
can have greater life. But the major problem with composites is higher initial cost.

Project 30

Tittle: THERMAL ANALYSIS OF CLAMSHELL HEAT EXCHANGER

ABSTRACT

Clamshell Heat exchangers are used in the residential furnaces, for room
heating purposes. The clamshell heat exchanger is subjected to heating and cooling
cycles alternatively. The hot gases after combustion in the burner flows through the
heat exchanger for 150 seconds heating the clamshell heat exchanger. This
constitutes the heating cycle. The flow of hot gases from the burner is stopped
after the completion of heating cycle. Now the cold air from the atmosphere is
blown over the hot clamshell heat exchanger for next 150seconds. Thereby heating
the air and cooling the clamshell heat exchanger. This constitutes the cooling
cycle .In this process of heating and cooling in small time span of 150seconds, the
clamshell is subjected to large thermal stress variations. These stress variations
induce the thermal fatigue in the material and lead to formation of cracks in the
clamshell heat exchanger.

The heating and cooling cycles are simulated using the principles of Finite
element methods and the analysis software ANSYS 7.1. Firstly, the transient fluid
flow analysis of gas flow region is performed to plot the velocity, pressure and
temperature distributions in it. After the combustion in the burner, the gases attain
°
a temperature of 1020 F. These gases are blown into the heat exchanger with the
help of an indoor blower for 150 seconds. The pressure gradient induced by the
blower (∆ p = 0.0093128 lb/in2) and temperature of the gases from the burner
°
(1020 F) are applied as boundary conditions for the fluid flow analysis of gas flow
region. With the obtained temperature distribution in the gas flow region as input,
the thermal analysis of clamshell heat exchanger is performed to plot the
temperature distribution in it. With the obtained temperature distribution in the
clamshell heat exchanger as input, the structural analysis of clamshell heat
exchanger is performed to plot the thermal stress distribution in it.

In the cooling cycle, the air is blown over the hot clamshell heat exchanger
with the help of the blower for next 150 seconds. For this purpose a two-inch airflow
region is modeled over the clamshell heat exchanger. The temperature distribution
in the clamshell heat exchanger after heating cycle is given as initial condition i.e.,
at t=0. The pressure gradient induced by the blower (∆ p = 0.127781e-3 lb/in2) is
applied as boundary condition. With the above initial and boundary conditions the
fluid flow analysis of airflow region over the clamshell heat exchanger is performed
to plot the velocity, pressure and temperature distributions in it. With the obtained
temperature distribution in the airflow region as input, the thermal analysis of
clamshell heat exchanger is performed to plot the temperature distribution in it.
With the obtained temperature distribution in the clamshell heat exchanger as
input, the structural analysis of clamshell heat exchanger is performed to plot the
thermal stress distribution in it. Using these stress distributions the thermal fatigue
life is calculated with the help of the Modified Goodman Diagram.

The clamshell heat exchanger is found to be failing after 9399.37 cycles due
to thermal fatigue near the first bend region. The large thermal gradient existing in
the region near the first bend is observed to be the critical parameter for the failure
of the clamshell heat exchanger

Title:Design and development of mounting bracket of Honda city

car using CAE techniques.

Imagine replacing metal with a strong durable thermoplastic compound. One

that consolidates parts to reduce expensive assembly and fabricating costs.

When we go for replacing metal parts with plastics, then so many

things come to our mind. Starting from material selection, we proceed with
the required design for the proposed plastic part to withstand the

requirements then the processing of the proposed part taken place.

Hence, part design plays a vital role because; in the case of plastics

the design of the part is done with a lot of care. Plastic part design is not as

simple as the metal part design. as The design of the plastic part is done by

taking a lot of things into consideration. Things like material selection and

processing of the designed part with the material directly depend on the

design of the part. A little mistake in design can lead to total part failure. So,

especially when we switchover to plastics from the metal side, we got to take

care of all the correct design factors as the strength of the plastic part will be

supposed to equal an exceed the strength of the metal part.

STRUCTURAL ANALYSIS OF AN L - SHAPED

ALUMINUM BEAM

SOFTWARE USED

ANSYS 8.0

TYPE OF ANALYSIS STEADY STATE

STRUCTURAL ANALYSIS

OBJECTIVE OF THE PROJECT

To find the stresses and deflections of a simple 'L'-shaped

aluminum beam with one end cantilevered and a point load at the
other end
 ABSTRACT

An L-shaped aluminum beam cantilevered at one end and subject to a

concentrated load at the free end is used to study stress and strain
transformations along with principal stress and strain calculations.
Equations of solid mechanics can be used to calculate the state of
stress at a point close to the cantilevered edge and on the
longitudinal axis of the beam. Stress transformation equations are
then used to evaluate principal and Von-Mises stresses. Then, ansys
finite element package is used to evaluate Von-Mises stress for the L-
shaped beam at the same point where the states of stress and strain
were defined.

"L"-shaped aluminum beam with one end cantilevered and a point

load at the other end is created using Ansys 8.0 software which
works on finite element method. The model is being created using
Direct Generation Method (creating nodes and elements). To find the
stresses, deflections and bending moment when point load is applied
on other end.

FINITE ELEMENT ANALYSIS OF TUNING FORK

■*

SOFTWARE USED

ANSYS 8.0

ANALYSIS TYPE

MODAL ANALYSIS

OBJECTIVE OF THE PROJECT

To determine the vibration characteristics (natural frequencies

and mode shapes) of a Tuning fork.
 ABSTRACT

Every component is subjected to vibrations due to natural frequencies

and at resonating frequencies we get different mode shapes. While developing
prototype of a component, it is required to find out all the natural frequencies the
corresponding mode shapes. Frequencies beyond a certain values badly effects
the functionalities of the component and after the Modal Analysis, if we find that
the values are beyond the desirable range, than we will have to either change
the design or material. The vibration characteristics (natural frequencies and
mode shapes) of a structure or a machine component can also be the starting
point for another, more detailed, dynamic analysis, such as a transient dynamic
analysis, a harmonic response analysis, or a spectrum analysis. The natural
frequencies and mode shapes are important parameters in the design of a
structure for dynamic loading conditions.

Thermal Analysis of Railway Wagon Brake Shoe

Analysis and Design of Underground Storage Tanks of

Polyethylene and Polymers.

Analysis of Ship Structures

Integrated approach through CAE for Design & Devlopment of a

Cooling Fan used in a Hand-Grinding Machine.

Design development of air intake manifold for four wheeler

engine.

Design and exploration of bumper systems using advanced cae

techniquces.

Design & Structural analysis through cae of gear control box

housing used for manual transmission in four wheeler.