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© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Student Details
Name

Department Mechanical Engineering

Year of Study 2nd Year

College Name MNIT Jaipur

University Name MNIT Jaipur

Email 2015ume1314@mnit.ac.in

Phone 8387865683

HOD Name & Contact Prof. G. S. Dangayach , hod.mech@mnit.ac.in , Phone no. - 0141- 2713330
detail
Reference professor Dr. Dinesh Kumar Mob No.- 9549654562 dkumar.mech@mnit.ac.in
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Student Comments
Problem Attempted

Part A Attempted , Brake pedal Analysis and Optimization

Part B

Part C Attempted , Multi Body Dynamics using Motion View and Motion Solve of
Stirling Engine.
Part D

Part E

Comments I have attempted two parts in which part A was compulsory . And I choose
part C to perform the MBD.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Contest Structure
Sectio Problem Marks Total
n Marks
Part A Optistruct 15 Marks for Geometry Cleanup & Mid-surface Extraction , 50
25 Marks Meshing + Quality Checks ,
10 Marks for Free –Free Run

Part B Radioss 25 Marks for Non-Linear Analysis, correlation & report 25

Part C MotionView/ 15 Marks for Modeling and Dynamic Simulation 25


MotionSolve 10 Marks for result correlation & report

Part D AcuSolve 10 Marks for Geometry preparation & Meshing each 25


15 Marks for Analysis& report

Part E User 5 Marks for difficulty of Model selection 25


Defined 5 Marks for Meshing and Geometry Editing
10 Marks for one type of different type of Simulation using Altair Solvers (i.e. Linear - OptiStruct,
Non-Linear-RADIOSS, MBD-MotionSolve, CFD-AcuSolve)
5 Marks for Optimisation using OptiStruct
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

General notes to student report


Report Format Structure Note:
• Use attached flow of result PPT with templet • Part A is Compulsory Section of
50 Marks
• Add necessary slides to explain
• Apart from Part A student has to
• Add necessary graph screenshot description for
complete any one of Part B, C,
your result
D, E of 25 Marks
• You can add your calculation
• You can add table for your result
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

General notes to student report


General notes
• Use HyperWorks Student Edition 14 for solving
all problems
• For any Technical query use Support Forum
http://forum.altairhyperworks.com/index.php?/for
um/77-edu-india-support-forums/
• Read all Terms and Condition & FAQ:
• Terms and Condition
• FAQs
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Problem Overview and Assumptions


• Problem Overview – Brake Pedal is most commonly used terms in Automobiles . This
part is used to multiply and transfer the Force with required mechanism . The Structure
needs to be strong enough to withstand abuse loading during Panic Braking ;mechanism
it should not be overdesign . The Problem emphasises on the Structural Analysis &
optimization of Brake Pedal.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Assumptions-

. Deflections should be small relative to structure.

. Material should be linear elastic.

. Boundary conditions should be constant.


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Model Pictures and information


• In this image we can see the proper quad meshing of the model and also the applied force is
also there . In the non design space there are constraints and rigids.
• Parameters –
Element type – Hex
Avg Element Size – 1.2mm
• Quality Criteria –
Warp Angle : <15
Aspect Ratio: <5
Min Element Size: 0.6mm
Max Element Size: 1.8mm
Jacobian : >0.5
Quad face included angle :45 <θ <135
Penta :< 5%
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Meshing-
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result of Analysis and Detail


• Maximum Von Misses Stress- 2.023E+01
• Averaging Method – Simple
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Maximum Displacement – 9.446E-02


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Node Deviation and Other Images-


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Videos of Analysis-
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Result of Optimization and Details-


• Here the Optimization is done of the Design space so maximum element density is at Non
Design space. Basically in Optimization we remove the material where the stress is very low.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Observation and Discussion-


• In analysis portion we have seen the maximum displacement and maximum stress. Maximum
displacement is at the first(starting) portion of the brake pedal . And maximum stress is
occurring at he middle portion of the brake pedal.

• Here we have performed the linear static analysis and all the conditions is only for linear
analysis.

• Clearly we can see that the force is applied at the very first ( top) portion of the brake pedal
but the stress is not maximum at that part of the pedal but it is maximum at the middle part or
else we can say at the design space . Where it is constrained.

• We can compare this structure as a cantilever beam, where the load is applied at he hanged
part and constrained at the back.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Observation and Discussion-


• Second thing is about optimization. Here we did optistruct optimization. In optimization the
material removed from the Design Space of the Brake Pedal. We saw that stress generated
is not throughout the design space.

• At some place the stress is high and at some place it is minimum. So the material is
removed from that place.

• We can’t remove the material from the Non Design Space because this part came in direct
contact with the user and if we removed the material from this place then this part will not
work according the use of it.

• By doing the optimization the Production cost of the material would decrease significantly.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary
• After attempting this problem statement I got knowledge of this software tool. By doing the
analysis and optimization we can check the product without having the product virtually.

• It tells about most affected region of the product and how we can utilize the product to
increase the life of the product.

• It also tells us how we can get less production cost and easy manufacturing by optimization.

• It also gave us the opportunity to understand the behaviour of a product under different
loading conditions.

• In this particular problem statement we have checked the behaviour of Brake pedal under a
certain load and did the optimization to remove the unnecessary material.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Problem Overview and Assumptions


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Model and Result Pictures and information


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Pictures and Detail


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Observations and Discussion


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Problem Overview
• In this problem statement we have stirling engine mechanism run by power unit. This power
unit is solar panel actuated. The solar Stirling engine can use the concentrated heat from the
sun as fuel to produce work. Hot side cylinder and piston assembly placed towards large dish
of mirror where solar ray concentrating and cold side cylinder and piston assembly kept at
cold side. Here is the flywheel is rotating at some constant rpm and we have to measure the
displacements, forces and velocities acting on piston-1 and piston-2.

Assumptions-
• If the nodes exceeds from 100,000 then .H3d file will not be generated. So to minimize the
nodes we have done coarse mesh at the power unit portion and fine mesh on the rest of the
portion.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Model and Result Pictures and information


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Information-
• No. of joints – 10
• Types of joints – Revolute , Fixed , Translational
• Fixed joint – Between Power Unit and Ground Body
• Fixed joint – Between Power Unit and Fix Base
• Fixed joint – Between Fix Base and Fix Base 2
• Revolute joint – Between Crank shaft and Piston crank connector
• Revolute joint - Between Connecting rod and Crank shaft
• Revolute joint – Between Connecting rod and Cold side piston
• Revolute joint – Between Piston crank Connector and Hot side piston
• Revolute joint – Between Power unit and Crank shaft
• Translational joint – Between Cold side piston and Fix base
• Translational Joint- Between Fix base and Hot side piston
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Working Animation-
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Pictures and Detail


• Displacement vs Time graph for piston-1,piston-2, flywheel (input).
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Maximum Displacement of piston 1

• Maximum Displacement of piston 2


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Velocity vs Time graph for piston-1, piston-2 , flywheel (input).


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Maximum Velocity of piston-1

• Maximum Velocity of piston-2


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Force vs Time graph for piston-1, flywheel(input)

• Maximum Force of piston-1


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

• Force vs Time graph for piston-2 , flywheel(input)

• Maximum force of piston-2


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Observations and Discussion


• Here total no. of joints are 10.
• One motion is given to the flywheel to rotate it at constant rpm.
• Six type of output created to know the velocity, displacement and force of each piston.
• Maximum displacement of piston-2 is more than piston-1.
• Maximum velocity of piston-1 is more than piston-2.
• Maximum force acting on piston-2 is more than piston-1.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary
• Here one flywheel is rotated by two piston or vice versa.
• By doing the Multi body dynamics simulation we have generated the graphs between the
displacement and time.
• By this problem statement we learned that how we can convert reciprocating motion to rotary
motion.
• This tool gives us the opportunity to understand the motion of a mechanism.
• Kinematic analysis of a mechanism is important to understand the behaviour of a mechanism.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Problem Overview and Assumptions


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Model and Result Pictures and information


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Pictures and Detail


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Observations and Discussion


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Problem Overview and Assumptions


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Model and Result Pictures and information


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Pictures and Detail


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Result Observations and Discussion


© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Overall Experience
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

India EDU Support Team Contacts


Support Forum – http://tinyurl.com/edusupportindia
Email ID – edu-support@india.altair.com
Website - www.altairhyperworks.in/aoc

• Bangalore • Pune
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Bangalore – 103 Ph. 020-66026918-21 Fax – 020-
Ph:080-6629 4500, Fax 080- 66026909
6629 4700
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