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ME 450 Group Adrian Conrad Chris Cook Thomas Hylton Nathan Wagers. High Pressure Water Fixture Conceptual Design Analysis December 10, 2007. Design Objectives. Demonstrate understanding of FEA through ANSYS Workbench.

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Me 450 group adrian conrad chris cook thomas hylton nathan wagers

ME 450 GroupAdrian ConradChris Cook Thomas HyltonNathan Wagers

High Pressure Water Fixture

Conceptual Design Analysis

December 10, 2007


Design objectives

Design Objectives

  • Demonstrate understanding of FEA through ANSYS Workbench.

  • Analysis had to prove that the current design was safe to operate under applied pressures.

  • Maximum stress would be below yield strength, therefore preventing plastic deformation.

  • Final analysis would allow for proper modifications to the fixture’s overall design.


Introduction

Introduction

  • High Pressure Water Fixture designed to flow water through interior of an airfoil to clean out any extra debris.


Introduction1

Introduction

  • 4,000 psi water flowing into fixture.

  • Stainless Steel fixture material.

  • Arbor adjustability

  • Fixture Dimensions:

    - Height: 4.5”

    - Length: 12”

    - Width: 5”


Element types

Element Types

  • 186 and 187 type elements

    • Used for Curved Surfaces

    • More nodes allows surface conformability

10 Node Tetrahedral Element

4 Node Tetrahedral Element


Utilized theory

Utilized Theory

  • Maximum Displacement

    • For u, v, & w components

  • Von Mises Stress


Utilized theory contd

Utilized Theory Contd…

  • Strain

    Where:

    And:


Model details

Model Details

  • Pro/E Model

    • Assembly of 34 Components

  • IGES File Creation

    • Solid Type


Fea tool ansys workbench

FEA Tool: ANSYS Workbench

  • Why?

    • Efficient Meshing

      • Automatic Mesh

    • Ease of Use for Refinement

      • Large Contact Edges

      • Arbor Bottom Edges


Iges file import

IGES File Import


Iges file import 2

IGES File Import (2)

Large Contact

Large Contacts

Swivel

Arbor Cap

Arbor

Long Rods

Long Rods

Swivel Case

Socket Bolt

Base Side

Base Top


Model details material

Model Details: Material

Stainless Steel AISI 304


Geometry connections

Geometry Connections

  • Default Contact Regions

  • Need for Fixed Constraints

    • Large Contact to Threads of 2 Long Rods

    • Base of Arbor to Socket Bolt

    • Large Contacts to 2 Swivels

    • Fixed Support


Connections large contact to 1 st rod

Connections: Large Contact to 1st Rod


Connections large contact to 2 nd rod

Connections: Large Contact to 2nd Rod


Connections arbor to socket bolt

Connections: Arbor to Socket Bolt


Connections large contact to 1 st swivel

Connections: Large Contact to 1st Swivel


Connections large contact to 2 nd swivel

Connections: Large Contact to 2nd Swivel


Fixed support

Fixed Support


Defined loads

Defined Loads

  • Worst Case Scenario

    • Maximum Pressure

  • Uniformly Distributed Force

    • (4000 psi = 27.579 MPa)

    • Perpendicular to Large Contact Faces


Defined loads 2

Defined Loads (2)

  • Ramp Loading of Pressure Forces

  • Approximation of Quick Turn-On of Pressure Washer


Defined loads 3

Defined Loads (3)


Defined loads 4

Defined Loads (4)


Me 450 group adrian conrad chris cook thomas hylton nathan wagers

Mesh

  • Two Different Sizes Used

    • Relevance Center

      • Coarse

      • Fine

  • Why?

    • To compare accuracy of displacements and stresses


Mesh 2

Mesh (2)

  • Types of Elements

    • SOLID 186

      • High Order 20-node Brick Elements

    • SOLID 187

      • 10-node Quadratic Tetrahedral (H) Elements

    • CONTACT 170/174

      • Part to Part Interaction for Assemblies

      • High End Surface to Surface Contact Elements


Coarse mesh

Coarse Mesh


Coarse mesh holes and edges

Coarse Mesh: Holes and Edges

  • Projected Higher Stresses

    • Large Contact Holes

    • Arbor Base Edges

  • Refinement of Mesh

    • Number of Divisions

      • 15 Elements per Hole

    • Size of Elements

      • 0.001 m for Edges


Coarse mesh holes and edges 2

Coarse Mesh: Holes and Edges (2)

= Hole Refinement

= Edge Refinement


Coarse mesh number of divisions

Coarse Mesh: Number of Divisions


Coarse mesh number of divisions 2

Coarse Mesh: Number of Divisions (2)


Fine mesh

Fine Mesh

  • Relevance Center: Fine

  • Refinement of Mesh

    • Number of Divisions

      • 30 Elements per Hole


Fine mesh 2

Fine Mesh (2)


Fine mesh 21

Fine Mesh (2)


Coarse vs fine mesh

Coarse vs. Fine Mesh


Analyzing the results

Analyzing the Results

  • Analysis to look at

    • Total Deformation

    • Equivalent (von Mises) Stresses

      • Locate Problem Areas

  • Comparison of Problem Areas

    • Coarse and Fine Mesh

    • Brick and Tetrahedral Meshes of Large Contacts


Total deformation

Total Deformation

Fine Mesh

Coarse Mesh


Equivalent stress and problem areas

Equivalent Stress and Problem Areas

Fine Mesh

Coarse Mesh

Problem Areas


Problem areas

Problem Areas

  • Threaded Holes Through Large Contacts

  • Closer Inspection

    • Brick Mesh

    • Tetrahedral Mesh

    • Equivalent Stress

      • Yield Strength of 205MPa

      • Tensile Strength of 515MPa


Tetrahedral meshed large contact

Tetrahedral Meshed Large Contact

Equivalent Stress

Fine Mesh

Max Stress = 3,500 MPa

Coarse Mesh

Max Stress = 3,500 MPa


Brick meshed large contact

Brick Meshed Large Contact

Equivalent Stress

Fine Mesh

Max Stress = 2,000 MPa

Coarse Mesh

Max Stress = 1,700 MPa


Summary of results

Summary of Results

  • Total Deformation Seemed Acceptable

  • Equivalent Stresses Highlighted Problems

  • Problem Areas

    • Tetrahedral Meshed Large Contact

      • Coarse and Fine Mesh – Over yield

    • Brick Meshed Large Contact

      • Coarse and Fine Mesh – Over yield

  • Design Not Acceptable


Design suggestions

Design Suggestions

  • Thicken the two connecting rods

  • Thread size increase

  • Large Contact thickness increase

  • Add additional connecting rod


Impact statement

Impact Statement

  • High Pressure Water Flow

    - Successfully clean interior of airfoil

    - Possibility of injury

  • Current Design

    - Inner Rod diameters too small

    - Further development/analysis on overall fixture

  • Safety of overall design/operation still a major concern.


Questions

Questions?


References

References

  • Moaveni, Saeed. Finite Element Analysis: Theory and Applications with ANSYS, 3rd Ed., Pearson Prentice Hall, Upper Saddle River, NJ, 2007, 30 Oct 2007.

  • Nema, K., Akay, H.U., Ch 13 Three Dimensional Elements, Department of Mechanical Engineering, IUPUI, Indianapolis, IN, 3 March, 2004, 23 Oct 2007.

  • http://www.efunda.com/materials/alloys/stainless_steels/ 11/26/07


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