ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY (ARJST)

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1 ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY (ARJST) LIFE PREDICTION ANALYSIS AND REDUCTION OF VIBRATIONS USING GEOMETRIC OPTIMIZATION TECHNIQUE FOR FRONT AXLE ASSEMBLY Mulkanoori Mahendar 1, S.L. Narasimha Reddy 2. 1Research Scholar, Department of Mechanical Engineering, Siddhartha Institute of Engineering and Technology, Ibrahimpatnam, Telangana, India. 2Professor, Department of Mechanical Engineering, Siddhartha Institute of Engineering and Technology, Ibrahimpatnam, Telangana, India. 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. In the former case, bearings or bushings are provided at the mounting points where the axle is supported. In the latter case, a bearing or bushing sits inside the hole in the wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type is referred to as a spindle. The aim of this project work is to improve Front axle life and reducing vibration effect by optimizing the geometry and by implementing new materials. In first step data collection and letauracher survey will be done to observe previous studys and material selection, In the next step Front Axle model along with wheel and leaf spring assembly will be generated for further study in FEM software, In the next step fatigue life analysis will be done on Front Axle model along with wheel and leaf spring assembly to find the life and failure locations, Geometry will be modified using above FEM results to reduce stress and vibration effects. By using above analysis results best design along with best material will be concluded. *Corresponding Author: Mulkanoori Mahendar, Research Scholar, Department of Mechanical Engineering, Siddhartha Institute of Engineering And Technology, Ibrahimpatnam, Telangana,India. arjstjournals@gmail.com IDOAJ Year of publication: 2015 Review Type: peer reviewed Volume: II, Issue : I Citation: Mulkanoori Mahendar,Research Scholar, "Life Prediction Analysis and Reduction of Vibrations Using Geometric Optimization Technique For Front Axle Assembly" Advanced Research Journals of Science and Technology (ARJST) (2015) Describe the linking mechanism of front axle and steering wheel, and Understand the steering geometry Axle 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. In the former case, bearings or bushings are provided at the mounting points where the axle is supported. In the latter case, a bearing or bushing sits inside the hole in the wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type is referred to as a spindle. INTRODUCTION In any motor cars and other four and six wheeler vehicles, steering is main component. Properly designed steering, works well and guides the vehicle to move in correct direction. Mainly steering is linked to the front axle with gear train mechanism. On the front axle, wheels are mounted, and with the help of steering wheel, the driver can turn the vehicle in right, left or straight directions. The function of steering mechanism is clearly explained in this unit. In this unit, we also elaborated on the front axle and its types. Principle of steering, steering geometry, steering gearbox and working of steering systems have been clearly explained. Objectives After studying this unit, you should be able to Understand about front axle and steering, Define function of front axle and steering, Explain the principle of steering mechanism, Vehicle axles Axles are an integral component of a wheeled vehicle. In a live-axle suspension system, the axles serve to transmit driving torque to the wheel, as well as to maintain the position of the wheels relative to each other and to the vehicle body. The axles in this system must also bear the 61

2 weight of the vehicle plus any cargo. A non-driving axle, such as the front beam axle in Heavy duty trucks and some 2 wheel drive light trucks and vans, will have no shaft. It serves only as a suspension and steering component. Conversely, many front wheel drive cars have a solid rear beam axle. solution for the manufacturing enterprise, with associative applications, robust responsiveness and web connectivity that make it the ideal flexible engineering solution to accelerate innovations. Catia-v5 provides easy to use solution tailored to the needs of small medium sized enterprises as well as large industrial corporations in all industries, consumer goods, fabrications and assembly. Electrical and electronics goods, automotive, aerospace, shipbuilding and plant design. It is user friendly solid and surface modeling can be done easily. 3D MODELING OF FRONT AXLE INTRODUCTION TO CATIA-V5 INTRODUCTION TECHNOLOGY OF CAD PRODUCT DEVELOPMENT THROUGH CAD PROCESS CAD TOOLS GEOMETRIC MODELING INTRODUCTION TO COMPUTER AIDED DESIGN Computer Aided Design (CAD) is a technique in which man and machine are blended in to problem solving team, intimately coupling the best characteristics of each. The result of this combination works better than either man or machine would work alone, and by using a multi discipline approach, it offers the advantages of integrated team work. The advances in Computer Science and Technology resulted in the emergence of very powerful hardware and software tool. It offers scope for use in the entire design process resulting in improvement in the quality of design. The emergency of CAD as a field of specialization will help the engineer to acquire the knowledge and skills needed in the use of these tools in an efficient and effective way on the design process. Computer Aided Design is an interactive process, where the exchange of information between the designer and the computer is made as simple and effective as possible. Computer aided design encompasses a wide variety of computer based methodologies and tools for a spectrum of engineering activities planning, analysis, detailing, drafting, construction, manufacturing, monitoring, management, process control and maintenance. CAD is more concerned with the use of computer-based tools to support the entire life cycle of engineering system. CATIA-V5 is the industry s de facto standard 3D mechanical design suit. It is the world s leading CAD/CAM /CAE software, gives a broad range of integrated solutions to cover all aspects of product design and manufacturing. Much of its success can be attributed to its technology which spurs its customer s to more quickly and consistently innovate a new robust, parametric, feature based model. Because that CATIA-V5 is unmatched in this field, in all processes, in all countries, in all kind of companies along the supply chains. Catia-v5 is also the perfect The above image shows front axle final model INTRODUCTION TO FEA Finite element analysis (FEA) is a fairly recent discipline crossing the boundaries of mathematics, physics, engineering and computer science. The method has wide application and enjoys extensive utilization in the structural, thermal and fluid analysis areas. The finite element method is comprised of three major phases: (1) pre-processing, in which the analyst develops a finite element mesh to divide the subject geometry into subdomains for mathematical analysis, and applies material properties and boundary conditions, (2) solution, during which the program derives the governing matrix equations from the model and solves for the primary quantities, and (3) post-processing, in which the analyst checks the validity of the solution, examines the values of primary quantities (such as displacements and stresses), and derives and examines additional quantities (such as specialized stresses and error indicators). The advantages of FEA are numerous and important. A new design concept may be modeled to determine its real world behavior under various load environments, and may therefore be refined prior to the creation of drawings, when few dollars have been committed and changes are inexpensive. Once a detailed CAD model has been developed, FEA can analyze the design in detail, saving time and money by reducing the number of prototypes required. An existing product which is experiencing a field problem, or is simply being improved, can be analyzed to speed an engineering change and reduce its cost. In addition, FEA can be performed on increasingly affordable computer workstations and personal computers, and professional assistance is available. 62

3 MATERIAL PROPERTIES AND BOUNDARY CONDI- TIONS Mild steel STRUCTURAL ANALYSIS ON FRONT AXLE EXISTING MODEL Material: mild steel The above image shows imported model E glass epoxy The above image shows meshed model The above image shows load applied S 2 glass epoxy The above image shows total deformation 63

4 The above image shows stress STRUCTURAL ANALYSIS ON FRONT AXLE EXISTING MODEL The above image shows total deformation mode The above image shows total deformation mode The above image shows total deformation FATIGUE ANALYSIS ON FRONT AXLE EXISTING MOD- EL The above image shows stress MODEL ANALYSIS ON FRONT AXLE EXISTING MODEL The above image shows life The above image shows total deformation mode The above image shows damage 64

5 STRUCTURAL ANALYSIS The above image shows safety factor The above graph shows Total deformation The above image shows Biaxiality indication STRUCTURAL ANALYSIS ON FRONT AXLE MODIFIED MODEL The above graph shows Stress The above image shows total deformation MODEL ANALYSIS The above graph shows strain The above image shows stress 65

6 CONCLUSION This project work deals with life prediction analysis and reduction of vibrations using geometric optimization technique for front axle assembly.to suggest modifications and material by doing fatigue life analysis to increase life, reduce weight & vibrations. Initially letrecher survey is done on axle analysis to observe previous researches /studies. Axle, wheel and leaf spring assembly was prepared and exported to ANSYS to conduct analysis. Structural analyses is done to analyze stress, strain and deformations at working load conditions, model analysis is done to evaluate vibrations in assembly, these vibrations depends on geometric shape and material, fatigue analysis is done to validate life cycles. Structural, model (vibrations) &fatigue analysis is done on assembly by varying materials to find failure locations, life and vibrations, stress consideration is mainly located on axle beam Geometric modifications are done to reduce stress concentration and vibration effect, above analysis is done to validate values/results As per the analysis results this project work concludes that, modifications in geometry will change the stress concentration and reduces the vibrations using s-2 glass carbon epoxy weight will be reduced by 69 % (factor of safety). Then traditional material and life will be increased by 100%while considering factor of safety. REFERENCES 1. Stress Analysis of Front Axle of JD 955 Combine Harvester Under Static Loading ALI JAFARI1,MAJID KHANALI, HOSSEIN MOBLI AND ALI RAJABIPOUR JOURNAL OF AGRICULTURE &SOCIAL SCIENCES 2. DESIGN AND ANALYSIS OF FRONT AXLE OF HEAVY COMMERCIAL VEHICLE Ketan Vijay Dhande1, Prashant Ulhe2 International Journal of Science, Technology & Management FATIGUE ANALYSIS 3. Directional Stability of Multi-Articulated Vehicles with Multiple Axles Akira AOKI**, Yoshitaka MARUMO** and Ichiro KAGEY- AMA** Journal of Mechanical Systems for Transportation and Logistics 4. Optimization of Tractor Trolley Axle for Reducing the Weight and Cost Using Finite Element Method I.D.Paul, G.P.Bhole, J.R.Chaudhari, Journal of Engineering, Computers & Applied Sciences (JEC&AS) The above graph shows safety factor 5. ANALYSIS AND DESIGN OF TRACTOR REAR AXLE USING FINITE ELEMENT METHOD- A REVIEW Piyush.C.Chaudhari1,Vimal.D.Sonara2, Dr.Pravin.P.Rathod3 International Journal of Advance Engineering and Research Development 66

7 6. Fatigue failure fault prediction of truck rear axle housing excited by random road roughness Meng Qinghua1*, Zheng Huifeng2 and Lv Fengjun3 International Journal of the Physical Sciences 7. Structural Analysis of Front axle beam of a Light Commercial Vehicle (LCV) Siddarth Dey#1, P.R.V.V.V Sri Rama Chandra Murthy. D #2, P.Baskar *3 International Journal of Engineering Trends and Technology (IJETT) 8. STATIC AND MODAL ANALYSIS OF REAR AXLE HOUS- ING OF A TRUCK G. Rajesh Babu and N. Amar Nageswara Rao AUTHOR Mulkanoori Mahendar, ResearchScholar, Department of Mechanical Engineering, Siddhartha Institute of Engineering And Technology, Ibrahimpatnam, Telangana,India. 9. Advancement in Simulation of Front Axle of Tractor Shantanu Ramesh Shinde International Journal of Engineering Research & Technology (IJERT) S.L. Narasimha Reddy, Professor, Department of Mechanical Engineering, Siddhartha Institute of Engineering And Technology, Ibrahimpatnam, Telangana,India. 67