engineering projects

ANALYSIS OF RESIDUAL STRESSES IN A BUTT WELD USING ANSYS SOFTWARE

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 0.115x0.048x0.006 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 (A2D 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.

WELDING SIMULATION OF ALUMINUM ALLOY JOINTS BY FINITE ELEMENT ANALYSIS

Simulations of the welding process for butt and tee joints using finite element analyses are to presented. The base metal is aluminum 2519-T87 and the filler material is alloy 2319. The simulations are performed with the commercial software ANSYS 5.6 a general purpose FEA software, which includes moving heat sources, temperature dependent material properties, metal plasticity and elasticity, transient heat transfer and mechanical analyses. One-way thermo-mechanical coupling is assumed, which means that the thermal analysis is completed first, followed by a separate mechanical analysis based on the thermal history. The residual stress state from a three-dimensional analysis of the butt joint is compared to previously published results. To reduce computer times for the tee, a model containing both solid and shell elements was attempted. Unfortunately, the mechanical analysis did not converge, which appears to be due to the transition elements used in this coupled solid-shell model. Welding simulations to predict residual stress states require three-dimensional analysis in the vicinity of the joint and these analyses are computationally intensive and difficult. Although the state of the art in welding simulations using finite elements has advanced, it does not appear at this time that such simulations are effective for parametric studies, much less to include in an optimization algorithm.

ANALYSIS OF RESIDUAL STRESSES IN A BUTT WELD USING ANSYS SOFTWARE

 

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 convergency 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.

FINITE ELEMENT ANALYSIS OF THE BENDING OF THE ROLLING MATERIAL IN ASYMMETRICAL SHEET ROLLING

Rolling is a process where the metal is compressed between two rolling rolls for reducing its cross sectional area. In a rolling process if the strip at the exit  of the rolls is bent either upward or downward than it leads  to a defect  known as front end bending of the strip and the rolling process in such condition is said to be asymmetric rolling. In asymmetric rolling process the work piece is bent to an unexpected shape. Its curvature may be caused by a speed difference, by lubricating mismatch or a radius difference of the work rolls ,and depends on various rolling parameters , such as ratio of peripheral  velocities of the upper roll and the lower roll, reduction ratio, average radius  of the work rolls, initial plate thickness and friction between the rolls and work piece. Front end bending may cause serious draw backs in terms of productivity and product quality. In addition, considerable damage to the equipment may result, especially when the bending is severe. Therefore it is of paramount importance to prevent front end bending to improve the product quality. Experiments in asymmetric rolling are more difficult than in conventional rolling because of the asymmetric tensile states. Numerical simulation techniques such as the FEM can provide a detailed study of the deformation state occurring in rolling process. Finite element simulation, which shows the influence of different diameters of the working rolls and of the degree of reduction on the bending of the work piece, has been performed in this work. The effect of various parameters on the front end bending of the work piece is discussed in this research. It is observed that the influence of the percentage deformation is greater than the influence of initial thickness in the front end bending of the plate. In this thesis a preliminary idea of developing a warping control system is discussed as a scope for the future research.

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B-Tech Project

FLUE GAS HEAT RECOVERY TO INCREASE BOILER EFFICIENCY

            The utilization of power in general is increasing day to day life. In this aspect the power can be generated in various methods. Mostly the power generated in the world is from coal & gas. But the lack of these resources, the power consumption is decreasing. Hence the importance of use of Biomass power plants is increased.

                             

                                  In this aspect the heat is to be recover to improve the boiler efficiency by the process named Quench Scrubbing. By this process we can also minimize emissions due to the contents present in the flue gases. The condensate from the chimney can be reuse as boiler makeup water. But the condensate is of low quality. To increase the quality, the condensate is passed through RO plant.

 

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B-Tech Project

STATIC ANALYSIS OF A COMPOSITE AUTOMOTIVE DRIVE SHAFT   

 As the natural resources goes on decreasing now a days and to meet the needs of natural resources conservation, energy economy most of the automobile manufacturers and their sub contractors are attempting to reduce the weight of the vehicles in recent years. In this approach they are searching for low cost, high strength to weight ratio materials. Substituting composite structures for conventional metallic structures in automobile industries has many advantages because of higher specific stiffness and strength of composite materials. Composite materials have the major advantage of high strength to weight ratio with continuously decreasing travel of cost in addition to other advantages like excellent corrosive resistance, superior torsional buckling and fatigue strength and high specific strain energy storage capacity.

The present work aims at the suitability of composite materials usage for the drive shafts in almost all automobiles at least those which correspond to design with rear wheel drive and front engine installation. The weight reduction of the drive shaft can have a certain role in the general weight reduction of the vehicle and is a highly desirable goal, if it can be achieved without increase in cost and decrease in quality and reliability. It is possible to reduce the weight of the drive shaft considerably by optimizing the design parameters by satisfying the all constraints.

This work deals with the design, material selection, optimum stacking sequence, and performance of composite drive shaft for passenger cars, small trucks and vans. Optimum design was made based on torsional stiffness formula and strength to weight ratio characteristics of solid to hollow shafts. Many reinforcements and matrix resin materials have been considered for material selection before the combination of e-glass/ carbon/ boron/ graphite  and epoxy resins was selected. More number of iterations was made for optimum stacking sequence based on number of layers, fiber orientation and sizing of radius for different combinations of reinforced and matrix resin materials. This study also aims to compare the performance of the composite drive shaft over steel drive shaft and suggested the suitability of composite materials in the automobile industries.

In this approach optimum designed drive shaft finite element model is prepared in finite element commercial software ANSYS 11.0. The static analysis was made on different materials and its combinations with matrix as epoxy resin for optimum number of layers, fiber orientation and optimum stacking sequence which are very much required for rotating elements like drive shafts.

  Static analysis is required for drive shaft is to evaluate based on torque transmission capacity along with angle of twist which should be with in limits of allowable shear stress. 

Key Words: Composite drive shaft, Stacking sequence, Weight reduction, Optimization, Epoxy resin

 

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B-Tech Project

Exhaust gas heat recovery power generating system

Now-a-days usage of electricity is increasing dad-by-day. For each and every work in homes, colleges, industries etc., are running by using electricity. Because of large usage resources are also decreasing so we have to conserve energy. The following experiment is also one of the best methods to conserve the energy. This experiment is done by using thermoelectric generator which converts heat into electricity directly this equipment has no moving parts and it is a silent operation.

          When compared to conservation of solar energy thermoelectric generator requires less space and it works continuous when it is exposed to heat whereas in solar energy it works only in day time as if we want to produce electricity during night time we have to track the sunlight and it requires more space high operational and maintenance cost etc., whereas in thermoelectric generator it is small in size and produces maximum power according to its capacity. Control unit, ammeter, temperature indicator is used to know how much voltage is produced at what temperature and battery is also used to charge the produced e.m.f. thermoelectric generator plays a main role in producing e.m.f. 

          Thermoelectric generators are all solid-state devices that convert heat into electricity. Unlike traditional dynamic heat engines, thermoelectric generators contain no moving parts and are completely silent. Such generators have been used reliably for over 30 years of maintenance-free operation in deep space probes such as the Voyager missions of NASA.1 Compared to large, traditional heat engines, thermoelectric generators have lower efficiency. But for small applications, thermoelectric can become competitive because they are compact, simple (inexpensive) and scalable.

          Thermoelectric systems can be easily designed to operate with small heat sources and small temperature differences. Such small generators could be mass produced for use in automotive waste heat recovery or home co-generation of heat and electricity. Thermoelectric have even been miniaturized to harvest body heat for powering a wristwatch.

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