1.

WEAR ANALYSIS ON CONTACT PRESSURE OF A DISC

BRAKE FOR PREDICTION OF SQUEAL GENERATION
ABSTRACT

Most mechanical systems that involve a sliding contact experience some degree of friction
induced self-excited vibration. An analytical approach was used to solve the equation of motion
of these annular discs for free vibration. The surface topographies of two brand new pairs of
brake pads are measured. The contact tests using pressure-indicating films are carried out in
order to capture static pressure distributions. The same brake pads are tested under several
braking applications. For each braking application, the static contact pressure distribution is
measured. These results will be then used to compare with the simulated results that we get from
the FE model. The natural frequencies of the annular disc are obtained using the analytical
approach. The importance of the finite difference technique lies in its ability to visualize the
results and provide deeper insights into the dynamics of brake rotors.

2. FINITE ELEMENT MODELING AND ANALYSIS OF INTERNAL
FIXATION DEVICES FOR DISTAL FEMUR BONE FRACTURES
ABSTRACT
The present work is focused on design and analysis of internal fixation devices for distal femur
bone fractures. It also presents the conceptual implant models for the fractures in distal femur
bone. The misaligned and unstable fractures of distal femur bone are treated by operative
incision using various internal fixations like Intramedullary nail, plates and Wires. The finite
element analysis was carried out during static loading condition which helps to compare the
stiffness and stress distributions of intact femur bone and fractured femur bone. It is observed
that stiffness value of the conceptual models is varied by changing the order of screw fixations of
the implants. The stiffness and stress distribution values of the intact model and conceptual
models are compared with previous literature. It shows the order of screw fixation improves the
significant amount of stiffness for distal fractured femur bone.
It is also observed from the results that the stiffness of conceptual model-1 (Intramedullary nail)
is more than that of conceptual model-2 (shield type plate) with respect to intact femur bone
when the screws are fully fixed . The stress distributions of conceptual model-1 are 15% more
than that of conceptual model-2.
These results are useful to understand the preferable conceptual implant model-1 to union the
fracture occurred in the distal femur bone with more stability.
3. FINITE ELEMENT ANALYSIS OF CONNECTING ROD
ABSTRACT
The main objective of the project is to study the effect of geometric parameters on the
stiffness of the big-end of connecting rod. In operation, the connecting rod is subjected to both
gas pressure and inertia loads, and therefore, it must be adequately strong and rigid and light in
weight as well.
Four models of the connecting rod are modeled using Catia with slight variations in their
geometric parameters. A connecting rod with less stresses in big-end is chosen to prevent the
failure of the connecting rod.
4. REDUCING EFFECT OF BENDING LOAD AND TORQUE LOAD
ON A HEAVY VEHICLE FRONT AXLE
ABSTRACT

An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle may
be fixed to the wheels, rotating with them, or fixed to its surroundings, with the wheels rotating
around the axle.
Conventionally the front axle is a dead axle. In such a case, the front axle beam is usually
a drop forging of steel. This type of axle is no more used in modern cars, although it is still being
used in heavier vehicles. The steels used for this are 0.4% carbon steel or 1.3% nickel steel.
The axle has to take bending loads due to weight of the vehicle and also torque loads due
to braking of the wheels. For this reason, front axle is made of I section in the central portion,
while the ends are made either circular or elliptical. A downward sweep is given to the center
portion to keep a low chassis height.
In our project, a basic model of front axle is prepared. The optimization of front axle is
done varying materials and its cross section. The present used material used steel. Steel is
replaced with Composite materials Glass Carbon and S 2 Glass epoxy to reduce the weight of
the axle. By reducing the weight, steering becomes easier.
Catia is used for modeling and ANSYS is used for analysis.
5. TURBINE BLADE VIBRATION ANALYSIS
ABSTRACT
Turbine blade failure is a very important problem in power plants. High cyclic fatigue is
the major cause for blade failure. For designing and estimating the life of existing blade it is
essential to correlate vibrations to the fatigue failure of blade .In the first part of this dissertation,
literature available on the vibration analysis, stress analysis of blade and S-N diagram approach
for failure analysis of turbine blade is explained.
In the second part failure analysis of uniform blade is done using FEM. Next to that
effect of cooling hole, pre-twist and taper on the blade failure is determined .At the end failure
analysis of a bladed disc is done using the cyclic symmetry approach in FEM.
6. DESIGN OF A STAIR WHEELER FOR WHEELED LUGGAGE
ABSTRACT
For many years people have been using luggage or more to the point lugging around
when they locomoted. Wheeled luggages are now heavily promoted for all types of travel. Its a
real boon for travelers to have luggage on wheels. It has undeniable advantages on any smooth
surfaces. Yet it's a nightmare to drag up stairs especially for heavy loads and along cobbled
streets.
The objective of this project was to design and test a user-friendly luggage models to be
used on staircases and to analyze issues common to customers. Several solid models were
created and a prototype was constructed. The device is portable which can be attached to the
luggage while using on staircases. It is a mechanical device includes case body, fixing frames,
and wheels, the frame is fixed in the rear part of the case body by the belts, and the wheels are
fixed at the bottom of the frame through a channel beam.
The finished prototype was tested with a pay load of approximately 20kg and it has
shown satisfactory results. The wheels are being towed, reducing the load burden on the user and
making it easier to pull the wheeled luggage over staircases. Luggage is dragged down freely it
needs further improvements while getting downstairs and it is a viable option for a stair climbing
consumer product.
7. DESIGN OF VALVE OPERATING SYSTEM FOR INTERNAL
COMBUSTION ENGINES
ABSTRACT
Internal Combustion Engines are the ones that have withstood the test of time and the
Poppet valve system is an indispensable part of the engine. The poppet valve system is found to
be extremely reliable, but the problem associated with this system is the high frictional loss and
large number of components. This is the motivation for the project, i.e., to develop a valve train
having lesser number of components, has reduced friction and wear, consumes least amount of
energy and at the same time is as effective as the poppet valve system from sealing point of view
and has low pumping losses. Various geometric designs of the valve train were developed and
detailed study of the feasible concept was carried out. Finally a convolution based poppet valve
system, which is free from numerous mechanical elements like the camshaft, cam, pushrod,
rocker arm and rocker bearing is proposed. Finite element analysis is carried out to obtain a
bellow that gives the desired valve lift and the stress levels are within the acceptable limits. The
same is validated experimentally to some extend by fabricating the bellows and taking trials.




8. Finite Element Modeling and Analysis of Spherical Indentation
Test
ABSTRACT

The spherical indentation test for measuring the stress-strain properties of materials has
become very popular with small specimen material testing technology. In the present work the
spherical indentation test setup has been modeled using finite element (FE) software ABAQUS
6.6-3 and the simulations have been run for elastic and elastic-plastic materials. The FE
simulation results of the elastic analysis have been verified with those from the Hertz analysis
and the results of the elastic-plastic analysis have been verified
from the experimental data thus validating the FE model. The spherical indentation
response outputs such as load versus indentation depth, pileup/
sink-in factor, Tabors plastic strain factor, and Francis constraint factor which can be
used in determining the stress-strain properties of the specimen have been examined through
dimensional analyses. These simulations were carried out to examine the effect of the strain
hardening index of the specimen material and the coefficient of static friction between the
indenter and the specimen on spherical indentation response. It was observed that the load-
indentation depth response is independent of coefficient of friction between the indenter and the
specimen. It was also concluded that the pile-up/sink-in factor and Francis constraint factor
obtained through simulations compare well with their measures reported in the literature.
However, the Tabors plastic strain factor obtained through simulations does not match well with
the values in the literature and hence cannot be reliably used to predict the stress-strain properties
of the specimen. Furthermore, it was concluded that the effect of elastic deformation of the
indenter on the load-depth response obtained from the experiments and the simulations cannot be
ignored.


9. DESIGN AND OPTIMIZATION OF SHELL-AND-TUBE HEAT
EXCHANGER FOR SPECIFIED PRESSURE DROPS
ABSTRACT

In a heat exchanger design, the allowable pressure drops of the streams are specified and
fixed ahead of the design exercise. In such situations, it is desirable to make full use of the
allowable pressure drops in order to minimize the size of the heat exchanger. The design
procedure therefore involves the determination of the maximum possible velocity (and hence
heat transfer coefficient). Design of shell-and-tube heat exchanger is complicated due to large
number of design variables like tube diameter, tube pitch, tube layout, baffle cut, baffle spacing,
shell diameter etc. Further the design method in general is iterative in nature and hence time
consuming.
This project is concerned with the formulation of thermal and hydro mechanical
design procedure for shell-and-tube heat exchanger for the required performance. It is intended
to estimate the minimum heat transfer area and consequent minimum cost for a heat exchanger
for given pressure drops while satisfying heat transfer requirements. The method developed for
the design of shell-and-tube heat exchanger is based on effectiveness-NTU approach. The total
number of transfer units, NTU, is distributed between shell and tube side. First step in the
effective consideration of allowable pressure drops is to establish a quantitative relationship
between velocity, allowable pressure drops, NTU, and heat transfer and friction factors. This
simple relationship is known as core velocity equation. Velocity of fluid is calculated from core
velocity equation. Once velocity is available, the approximate free flow area is obtained. Large
numbers of configurations are possible to satisfy the free flow area. The details of exchanger
geometry can then be determined from free flow area. After thermo hydraulic design, mechanical
design is done. Alterations if any in mechanical design, the modifications are taken account in
thermal design. The procedure is iterated till all constraints are satisfied.

An algorithm is developed for design and optimization of shell-and-tube heat exchanger
for specified pressure drops. A program has also been developed for mechanical design and
costing of shell-and-tube heat exchangers.
10. Parametric study of cutouts in the aircraft floor beams
ABSTRACT
The aircraft structure is continually faced with requirements for openings at webs and panels to
provide access or to let other members such as control rods or cables, hydraulic lines, electrical
wire bundles, etc., pass through. Other cutouts such as windows, doors, servicing panels, hatches,
bomb-bays, inspection access holes, etc. cause a recurring head-ache for structural engineer. As
soon as one makes a hole in a load-bearing skin, a stronger surrounding structure must be
introduced to provide alternate paths to carry the loads.
Cutouts in structure invariably increase the structural weight because the structure adjacent to the
cutout must be increased to carry the load which would have been carried in the cutout panel.
In our study, cutouts are made in the aircraft floor beams which are subjected to different loading
conditions like lightly, moderately and heavily loaded. The study is carried out to determine the
various parameters that are used in the design of the beam and how to obtain the desired strength
of beam by varying the parameters.
The parameters taken into account are the thickness of web, diameter of hole, allowable shear
flow through the web, height of the web.
The three loading conditions have their own design procedure, based on the loading value a
suitable procedure is adopted and the design is carried out.
As the loading value increases, we add extra material to the web namely stiffeners or doublers in
order to provide stiffness to the web. By adding of extra element, the weight increases, in order to
reduce the weight, the parameters are varied until the desired results are obtained.

These results are useful to understand the preferable conceptual implant model-1 to union
the fracture occurred in the distal femur bone with more stability.



FEA ANALYSYS OF JUTE,E-GLASS COMPOSITE MATERIAL USING ANSYS
Abstract
Composites fiber are moving into the main stream for the auto industry, with automakers and
suppliers finding more variations of bio composites, glass fibers and more places to use them
Natural fibers such as kenaf, hemp, flax, jute, and sisal offer such benefits as reductions in
weight, cost, and CO2, less reliance on foreign oil sources, and recyclability. Fibers like flax,
hemp or jute are cheap, have better stiffness per unit weight, corrosion resistance, electrical
insulation, reduction in tooling and assembly costs, low thermal expansion, higher stiffness and
strength, fatigue resistance and have a lower impact on the environment. A composite is a
heterogeneous material created by the synthetic assembly of two or more components
constituting reinforcing matrix and a compatible matrix to obtain specific characteristics and
properties.
In this project we Selected jute fiber, E-Glass and it is embedded in a biopolymer matrix
system(epoxy), the task of which is to hold the fibers together, this provides and stabilizes the
shape of the composite structure, transmits the shear forces between the mechanically high-
quality fibers, and protects them against radiation and other aggressive media. And the specimen
is prepared. The component is conditioned and prepared for testing and subjected to tensile test
and bending test.calculating the element results with ansys by using the test results.
The main aim of this project is to reduce the impact on the environment, by preparing
specimen using recyclable natural fibers.


9. FRACTURE ANALYSIS OF FRP COMPOSITES SUBJECTED TO
STATIC AND DYNAMIC LOADING
ABSTRACT
Analytical solution exists for relatively simple cases. Due to complicated boundary
conditions associated with the governing equations analytical approaches are used. Over the last
decade or so finite element method has been firmly established as a standard procedure for the
solution of practical fracture problems.
The usefulness of stress intensity factors (SIFs) in the analysis of the problems of
residual strength, fracture and fatigue crack growth rate has resulted in effort being expanded on
the determination of SIF.A number of techniques have been suggested for the validation of SIF
from the finite element results but adequate representation of crack tip singularity remains a
common problem to most of these method.
The objective of the present work is to investigate the Stress Intensity Factor (SIF) for
benchmark problems for static and dynamic loading in composite plates having center, edge.
Further the analysis is extended to CT specimen, plate with 3-point bend, v-notch and double
edge notch.
In the static analysis SIFs is to be found for an isotropic material using singular and j-
integral approach. For the orthotropic material SIF is to be found out for the above specimens
with Carbon UD/Epoxy, R Glass roving UD/epoxy, S2 glass fabric/epoxy material properties.
The Transient Dynamic analysis on the above specimens is to be carried out.

4. 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
theoreti cal met hods. The stresses generated and the deflections of the tooth have been
analyzed for different materials. Fi nal l y the resul ts obt ai ned by t heoreti cal anal ysis
and Finit e El ement Anal ysi s are compared t o check t he correctness. A conclusion
has been arrived on the material which is best suited for the marine engines based on the results.

ABSTRACT
The objective of the project is to make a comparision of the behavior of gears made of
five different materials i.e. Mild Steel, Cast Iron, Nickel Chromium Steel, Phosphor
Bronze, Graphite Epoxy Composite, under similar working conditions and hence
comparing the suitability of materials for the selected application. This is aided by design
of the gear in CATIA and structural analysis in ANSYS.
A C program has been formulated in order to perform all the calculations necessary for
the design and structural analysis. The purpose of formulating the C program is to
simplify the process of calculating the dimension and load parameters. Basic input such
as the dimensions of the gear, velocity ratio of the gear assembly and the speed of one of
the gears is sufficient to obtain the values of various loads acting on the weaker section
and the design parameters required. Also values for a particular material can be
obtained, by feeding the materials mechanical properties in the material bank.
Structural Analysis is carried out on the weaker section of the gear assembly with the
help of the output obtained from the C program. This is done for all the five materials
considered and aspects like deformation, stress intensity, von-mises stresses are noted.
These aspects of the materials are compared by plotting graphs and hence comparing the
suitability of the materials in different applications.
The results obtained help in the optimum selection of material for the required
application hence minimizing the probability of failure of the gear when in operation
which benefits the overall performance of the industry.



MODELLING AND ANALYSIS OF LOCOWHEEL USING ANSYS AND
FEA
ABSTRACT

The main objective of our project is to analyze the stresses induced in the given wheel
design, to evaluate its performance under normal railroad operating condition, i.e. under
mechanical loads like brake load and loads due to weight of bogies. In the work presented here,
Non linear thermal analysis with temperature dependent material properties and Linear stress
analysis of 43 loco wheel made of stainless steel have been reported with stress contours for
various combinations of loads.

For carrying out this work, Finite Element Analysis is employed. Finite Element
Analysis is a computer based numerical technique for calculating the strength and behavior of
engineering structures. It can be used to calculate deflection, stress, vibration buckling behavior
and many other phenomena. It can be used to analyze either small or large scale deflection under
loading or applied displacement. It can analyze elastic deformation or plastic deformation. The
computer is required because of astronomical number of calculations needed to analyze large
structures. The power and low cost of modern computers has made Finite Element Analysis
available to many engineering disciplines and companies.