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DESIGNING, MANUFACTURING AND ANALYZING OF

TENSILE TEST SPECIMEN WAS COMPARED WITH FEA


METHOD AND EXPERIMENTAL METHOD

A PROJECT REPORT

Submitted by

K.HARIPRASTH 510916402003

in partial fulfilment for the award of the degree


Of
MASTER OF ENGINEERING
IN
CAD/CAM

GLOBAL INSTITUTE OF ENGINEERING & TECHNOLOGY MELVISHARAM

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2017

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ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report DESIGNING, MANUFACTURING


AND ANALYZING OF TENSILE TEST SPECIMEN WAS
COMPARED WITH FEA METHOD AND EXPERIMENTAL
METHOD is the bonafide work of K.HARIPRASTH
510916402003 who carried out the project work under my supervision.

SIGNATURE OF HOD WITH DTAE SIGNATURE OF THE SUPERVISOR WITH DATE

Mrs.Y.ANITHA M.E.,(PhD) Mr.B.NIRMAL M.E.,


ASSISTANT PROFESSOR, ASSISTANT PROFESSOR,
Department of Mechanical Engineering, Department of Mechanical Engineering,

Global Institute of Engineering , Global Institute of Engineering ,

Technology, Melvisharam Technology, Melvisharam

Vellore District. Vellore district.

Submitted to the project Viva-voceExaminationheldon.

INTERNAL EXAMINER EXTERNALEXAMINER


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ACKNOWLEDGEMENT

With great pleasure and Gratitude, We express our Sincere thanks to our
beloved chairman for having permitted us to take up this project.

First and foremost, we wish to express our sincere thanks and gratitude to
Principal, Global Institute of Engineering and Technology for his kind
permission and providing us the facilities to make our project success.

We Would like to extendOur heartful thanks to Mrs.Y.Anitha


M.E.,(PhD)Head of the Department of Mechanical Engineering for his constant
encouragement and inspiration for the completion of project successfully.

We are grate to express our Sincere thanks to ourProject Coordinator


Mr.R.Nandhikumar,M.E.,Assistant Professor, Mechanical Engineeringfor his
special attention and guidance towards the completion of this project work.

We extend our thanks to all the staffs of our department for their kind co-
operation during the completion of this project.

We express our heart full thanks to all these who have directly and
indirectly contributed for the completion of our project.

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ABSTRACT
In the present study, investigating on the finite element modeling and analysis
of a tensile specimen has been carried out. The FEA model of the tensile
specimen has been prepared in ANSYS for finite element analysis, which is
most popular CAE tools. The finite element analysis of the tensile specimen has
been performed by discretization of the model in infinite nodes and elements
and refining them under defined boundary condition. Tensile stress results are
also calculated by experimental method. The finite element results using
ANSYS software showing stresses and deflections were verified with analytical
and experimental results. Computer simulations by using ANSYS 12.0 software
gave very consistent results with a variation of approximately 1-4 % which can
be considered as an acceptable range. Aluminium based experimental composite
specimens are prepared by latest casting route and the tensile strength was
estimated by universal testing machine.

Keywords:Ansys (FEA), Tensile test, UTM, Composites, Modeling

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CONTENTS

CHAPTER TITLE PAGE

ABSTRACT iv

CONTENTS v

LIST OF TABLE viii

List of figures ix

1. INTRODUCTION OF ANSYS 1

1.1 History of ANSYS 2


1.2 Steps involved in FEA 4
1.3 General Steps in FEA 6
1.4 Steps in Flow Chart 7
1.5 One Dimensional Element 9
1.6 Two Dimensional Element 9
1.7 Classification of FEA 10
1.7.1Discretization of Structure Aluminium 10

1.7.2 Number of Nodes 11

1.8 Advantages of FEA (ANSYS) 12

1.9 Disadvantages of FEA (ANSYS) 12

1.10 Application of FEA 12

1.11 Objectives 13

1.12 Scopes 13

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2. LITERATURE REVIEW 14

2.1 Objectives 16

3 INTRODUCTION OF COMPOSITE TENSILE SPECIMEN

3.1 Composite Material 17

3.2 History of Aluminium 6061 18

3.3 Physical Properties of Al 19

3.4 Stir casting 19

3.5 Chemical Composition 19

3.6 Reinforcement 20

3.7 Zirconium Oxide 20

3.8 Uses of Composites 21

4 INTRODUCTION OF TENSILE PROPERTIES

4.1 Uniaxial Tensile Testing 23

4.2 Stress and Strain Relationship 25

4.3 Youngs Modules 26

4.4 Ultimate Tensile Strength 27

4.5 FEA Method 27

4.6 Experimental Method 28

5 PREPARATION OF TENSILE SPECIMEN

5.1 FEA Method 29

5.2 Experimental Method 30

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6 PROJECT METHODOLOGY

6.1 Methodology 32

7 CALCULATION OF EXPERIMENTAL STUDY

7.1 Sample A 33

7.2 Sample B 33

7.3 Sample C 34

7.4 Sample D 34

8 RESULT AND DISCUSION

8.1 Comparison Study of Method 1 35

8.2 Comparison Study of Method 2 37

9 CONCLUSION 40

10 REFERENCES 41

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LIST OF TABLE

TABLE PAGE
TITLE
NO. NO.

1 Chemical composition of aluminium 19

2 Comparison of steel and AMC of tensile strength 37

Comparison of experimental and FEA result of tensile


3 39
strength

4 Cost estimation 43

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LIST OF FIGURES

FIGURE PAGE
TITLE
NO. NO.

1 Nodes and element 8

2 Discretization of Structure 10

3 Standard tensile specimen 24

4 Stress strain relationship 26

5 Tensile specimen as per ASTM under FEA 30

6 Tensile specimen as per ASTM under EXPT 31

7(a) AA6061 36

7(b) AA6061+3%ZrO2 36

7(c) AL6061+6%ZrO2 36

7(d) AL6061+9%ZrO2 36

8 Comparison Of AluminiumAnd AMC 37

9(a) AA6061 38

9(b) AL6061+3%ZrO2 38

9(c) AL6061+6%ZrO2 38

9(d) AL2014+9%ZrO2 38

10(a) Before testing 39

10(b) After testing 39

11 Comparison of FEA and Experimental results 40


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