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A Parametric FEA System for Fixturing of Thin-walled Cylindrical Components

A Parametric FEA System for Fixturing of Thin-walled Cylindrical Components. Presented By: Michael Cope October 29, 2008. Authors: Yan Wang; Jianfan Xie, Zhijian Wang; Nabil Gindy Accepted: 20 November 2007 by the Journal of Materials Processing Technology. Function.

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A Parametric FEA System for Fixturing of Thin-walled Cylindrical Components

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  1. A Parametric FEA System for Fixturing of Thin-walled Cylindrical Components Presented By: Michael Cope October 29, 2008 Authors: Yan Wang; Jianfan Xie, Zhijian Wang; Nabil Gindy Accepted: 20 November 2007 by the Journal of Materials Processing Technology

  2. Function • “Propose a parametric FEA system that can automatically mesh components, assign material properties and boundary conditions, and create FEA files ready for calculation with limited human interference (Page 338)”

  3. Why Does this Matter? • Current cylinders can be modeled parametrically, but the FEA still needs to be inputted by hand (Pg. 340) • Reducing Manufacturing costs while increasing component quality. (Pg. 338) • Reduce the # of Spoiled Parts

  4. References

  5. How Does this Relate to ME 482? For Turning Total cost per part: Cc = Co Th + Co Tm + Co Tt /np + Ct /np Substituting for Tm and np: Cc = Co Th + Co p DL/fv + (CoTt + Ct )pDLv(1/n -1)/( f C(1/n) )Minimizing cost per part (dCc/dv = 0) gives cutting speed and tool life to minimize machining costs per part: vmin = C{n Co/[(1 – n)(Ct + CoTt)]}n Tmin = (1 – n) (Ct + CoTt)/(n Co) What is Co? Operator Cost! Don’t forget Spoiled Products!

  6. Parameters

  7. Parameters Continued S The number of section of the angle-varying thin-walled cylinder T Thickness of the thin-walled cylinder TLi The tolerance constrains on the component during the ith step Tol Tolerance in the thickness direction on the thin-walled cylinder X(i, j, k) The X value regarding the CS of node N(i, j, k) XS boundary condition on X direction for XY symmetry Y(i, j, k) The Y value regarding the CS of node N(i, j, k) YS1 boundary condition on Y direction for X symmetry YS2 Boundary condition on Y direction for of XY symmetry Z(i, j, k) The Z value regarding the CS of node N(i, j, k) ˇ The angle of the component in the radius direction representing the symmetry boundary condition Poisson ratio

  8. Design Principles 3 Cylinder Types • Standard Thin Walled Cylinder • Conical Thin Walled Cylinder • Varying Angle Thin Walled Cylinder Assumptions: Elastic Deformation, Point Force, Rigid Fixture/Support (Pg. 340

  9. Design Principles cont…

  10. Experimental Equipment • ABAQUS FEA software used to analyze systems • Use of custom user interface to facilitate FEA

  11. Design Principle Application • After the user inputs all the parameters, the system crunches the math. • A fully usable file is then imported into ABAQUS

  12. Correlation of Results and the Model NONE!!!! • No testing to validate model! • “Much of the work to build a simulation is repeatable.” (Pg 346) • Even a comparison with “Hand” calculations would have been better

  13. Practical Use • Eliminate hours of work spent in FEA software • Greater communication between design and manufacture • Autonomy for the manufacturing engineer • Reduce the cost of developing thin-walled cylinders

  14. Technical Advancement • Accuracy Improved Manufacturing of parts • Reduced vibration and deformation • Opens the door for fully parametric FEA analysis software

  15. Industries Impacted • Aerospace • Automotive • Power

  16. Questions?

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