Professional Documents
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I.
INTRODUCTION
105
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
Year
2010-2011
2011-2012
2012-up to April 2013
Total no of failed
Axle
257
219
112
Density (g/cm3)
Poisson,s Ratio
Elastic modulus (GPa)
Tensile strength (MPa)
7.858
0.27 to 0.30
190-210
440
370
A. Modeling of Axle
PRO-E modeling software is used for modeling of
the bullock cart axle. The model has a solid axle shaft of
square cross sectional area of 58mmX58mm, machined
at both ends with length 1676 mm.
of Specification
Failed Axle
range (SAE 1025)
Relative
Frequency
0.7
Percentage
frequency
7%
15
27
33
18
0.15
0.27
0.33
0.18
15%
27%
33%
18%
1. Carbon (C)
0.22 to 0.28 %
0.22 %
Load (Kg)
Frequency
2. Manganese(Mn)
0.30 to 0.60 %
0.45 %
1-999
1000-1999
2000-2999
3000-3999
4000-5000
3. Silicon(Si)
0.15 to 0.35 %
0.17 %
4. Sulphur (S)
0.050% Max
0.023 %
5. Phosphorous(P)
0.040 % Max
0.030 %
106
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
C. Meshing
Critical areas are high stress locations. Dense
meshing & structured mesh (no Trias /pentas) is
recommended in these regions. Areas away from critical
are general areas.
Mesh refinement at
critical area with
mesh size in mm
Total
Deformation
in mm
Number of
node
4mm
0.1779
111801
3mm
0.1773
116152
2mm
0.1787
129998
1mm
0.1793
199363
0.9mm
0.1795
220687
0.8mm
0.1796
249336
0.7mm
0.1797
293463
0.6mm
0.1797
359374
D. Boundary condition
Loads and Boundary condition of axle are shown in
below figure.
107
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
E. Review Results
1) Deformation
The following figure shows the Total deformations
within the axle, when the 5 Tonne loads are applied.
A. Results Review
1) Deformation plot
The following figure shows the Equivalent (vonmises) stress on the axle when the 10 Tonne load is
applied. Red color shows the maximum stress and blue
color shows minimum stress generated on the axle.
108
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
Yield strength
(Existing Material of
Axle SAE 1025 )
370 MPa
Shear Force
5170 N
5170 N
20 N
-20 N
-5170 N
Bending Moment
0 N-mm
408430 N-mm
422190 N-mm
408430 N-mm
0 N-mm
Equivalent(Von-mises)
Stress For 10 Tonnene
loading
Bending Stress
(Existing Material
Axle SAE 1025 )
of
588.8 MPa
= (370/1.5)
= 246 MPa
Z=4141683.90/246
Z=16836.11 mm3
109
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
Density (g/cm3)
Poisson,s Ratio
7.872
0.27 to 0.30
210
710
605
1)
16836= (58*583-b*d3)/6D
b=d
b4=5457568
2) Define material
b= 48.3367= 48.50mm
d = 48.50mm
bd3=5457568
Built Geometry
3) Generate Mesh
B. Material selection
Mechanical Properties of suggested material SAE
1547 for solid axle
110
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
Total
Deformation
( mm)
Number of
node
0.3341
88491
6 mm
5 mm
4 mm
3 mm
2 mm
1 mm
0.3351
0.3356
0.3364
0.3377
0.3386
0.3387
89433
90955
92986
98365
112028
186783
0.9 mm
0.8mm
0.3688
0.3390
212463
242958
Yield strength of
suggested material for
solid axle (SAE 1547 )
Equivalent (Von-mises)
Stress developed within
suggested Axle due to
max loading Condition
605 MPa
440.43 MPa
1) Deformation plot
The following figure shows the Total deformations
within the axle, when the 10 Tonne loads are applied.
Sr.
no
Existing Axle
Proposed Axle
Combined Axle
Material SAE1547
(Solid axle) and
SAE 1025 (Hallow
axle)
111
FEA Analysis of Bullock cart Axle under Static and Dynamic Condition
[2]
[3]
[4]
[5]
[6]
[7]
Section
modulus=32518mm3
Section
modulus=16836 mm3
Weight 40Kg
Weight 31Kg
VIII. REFERENCES
[1]
112