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ABSTRACTS

1.DESIGN AND ANALYSIS OF ARMY VEHICLE CHASSIS


ABSTRACT

Chassis is a major component in a vehicle system. For vehicles, chassis consists of an assembly
of all the essential parts of a vehicle (without the body) to be ready for operation on the road.
This project deals with the analysis of the Army vehicle chassis for the different loading
conditions. Army vehicle chassis is steel welded Structure of size built on the vehicle. The Army
vehicle chassis is used for carrying Shelter mounted Electronic Equipment and its accessories.
The Army vehicle chassis design is optimized to keep the weight of the Army vehicle chassis to
the minimum.

Automobile chassis usually refers to the lower body of the vehicle including the tires, engine,
frame, driveline and suspension. Out of these, the frame provides necessary support to the
vehicle components placed on it. Also the frame should be strong enough to withstand shock,
twist, vibrations and other stresses.

In the current project design has been validated using finite element analysis. The following
analysis was carried out to study the structural integrity of the “Army vehicle chassis” under
various loading conditions. Unigraphics software is used for developing design and Ansys
software is used for analysis process.
2.DESIGN AND ANALYSIS OF HELICOPTER ROTOR HUB
FOR STRUTURAL LOADS

ABSTRACT:

The rotor system is the rotating part of a helicopter which generates lift. The rotor consists of a
mast, hub, and rotor blades. The mast is a hollow cylindrical metal shaft which extends upwards
from and is driven and sometimes supported by the transmission. At the top of the mast is the
attachment point for the rotor blades called the hub. The rotor blades are then attached to the hub
by any number of different methods. Main rotor systems are classified according to how the
main rotor blades are attached and move relative to the main rotor hub.

As the rotor spins, each blade responds to inputs from the control system to enable helicopter
control. The center of lift on the whole rotor system moves in response to these inputs to effect
pitch, roll, and upward motion. Here the helicopter rotor hub must carry the blade weight and
aerodynamic forces as rotational speeds. For that case, of helicopter rotor hub strength will be
calculated.

In this project, the 3D model of helicopter main rotor hub shall be done in
UNIGRAPHICS and imported into ANSYS software to perform static analysis to analyze
strength of rotor hub and optimize by using different materials.
3.DESIGN AND ANALYSIS OF LEAF SPRING

ABSTRACT

Leaf springs are one of the oldest suspension components they are still frequently used,
especially in commercial vehicles. The past literature survey shows that leaf springs are designed
as generalized force elements where the position, velocity and orientation of the axle mounting
gives the reaction forces in the chassis attachment positions. Another part has to be focused, is
the automobile industry has shown increased interest in the replacement of steel spring with
composite leaf spring due to high strength to weight ratio. Therefore, analysis of the composite
material becomes equally important to study the behavior of Composite Leaf Spring.

The objective is to compare the stresses, deformations and weight saving of composite leaf
spring with that of steel leaf spring. The design constraint is stiffness. The Automobile Industry
has great interest for replacement of steel leaf spring with that of composite leaf spring, since the
composite materials has high strength to weight ratio, good corrosion resistance. The material
selected was glass fibre reinforced polymer (E-glass/epoxy) , steel are used against conventional
steel.

The objective of project is to present modeling and analysis of composite mono leaf spring
(GFRP) and compare its results. Modeling is done using UNIGRAPHICS NX 7.5 and analysis is
carried out by using ANSYS 10.0 software for better understanding.
4.DESIGN AND STRESS ANALYSIS FOR MISSLE CONTROL COMPONENT

Abstract
Aerodynamic control is the connecting link between the guidance system and the flight
path of the missile. Effective control of the flight path requires smooth and exact operation of the
control surfaces of the missile. They must have the best possible design configuration for the
intended speed of the missile. The control surfaces must move with enough force to produce the
necessary change of direction. The adjustments they make must maintain the balance and center
of gravity of the missile. The control surfaces must also be positioned to meet variations in lift
and drag at different flight speeds. All these actions contribute to the in-flight stability of the
missile.

Missile control bays have been, and are arguably still, the most efficient means of
controlling a missile and guiding it to a target. They can efficiently generate the required
maneuvering force by a direct action near the center of gravity. Affecting all of these
aerodynamically controlled configurations are the sizing and power requirements of the control
surfaces.

In my project, a finite element model for strength analysis of a missile’s control bay is
carried out under different conditions like Pitch, Yaw and Roll moments. Characteristics of stress
distribution and high stress locations are determined according to the model.

UNIGRAPHICS software shall be used for 3D modeling of the control bay model and
Ansys software shall be used to perform the structural analysis of the control bay.

Keywords:

Maneuvering: A strategic or tactical military or naval moment


5.MODELING AND ANALYSIS OF DISC BRAKE

ABSTRACT
The disc brake or disk brake is a device for slowing or stopping the rotation of a wheel.
This is connected to the wheel and/or the axle. To stop the wheel, friction material in the form
of brake pads, mounted on a device called a brake caliper, is forced
mechanically,hydraulically,pneumatically or electromagnetically against both sides of the
disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion to heat,
and if the brakes get too hot, they become less effective, a phenomenon known as brake fade.

Due to the application of brakes on the car disk brake rotor, heat generation takes place
due to friction and this thermal flux has to be conducted and dispersed across the disk rotor cross
section. The condition of braking is very much severe and thus the thermal analysis has to be
carried out. The thermal loading as well as structure is axis-symmetric. Hence axis-symmetric
analysis can be performed, but in this study we performed 3-D analysis, which is an exact
representation for this thermal analysis.

Thermal analysis is carried out and with the above load structural analysis is also
performed for analyzing the stability of the structure. Modeling is done using UNIGRAPHICS
NX 7.5 and Analysis is carried out by using ANSYS software.
6.DESIGN OPTIMIZATION OF HYPOID GEAR BY USING
STRUCTURAL ANALYSIS

ABSTRACT

Hypoid gears are widely used to transmit crossed-axis power and motion in vehicles,
ships and aircrafts, and could offer higher load capability and axis position flexibility than spiral
bevel gears. Hypoid gears are bevel gears with nonintersecting axes where the hypoid offset is
defined as the shortest distance between these two axes. Hypoid gears are preferred over bevel
gears without offset if aspects of gear noise or of installation space are in focus.

The hypoid gear sets are very sensitive to the precise contact conditions. Assembling test
rigs is expensive and time consuming, whilst Finite Element analysis of the complete system can
be problematic due to non-linear contact. The gear sets in actual vehicles are supported by a
number of other components, and deformation of these components in operation produces
different gear meshing positions to those observed when the gears are unloaded. These changes
in meshing position increase the stress on the tooth roots. A hypoid gear tooth root stress
simulation that considers the stiffness of the supporting components was therefore developed.

The dynamic characteristics analysis of hypoid gear is mainly involved in the calculation
about natural frequency and operating frequency. The objective is to calculate the natural
frequency and operating frequency of hypoid gear is modulating those frequencies and avoiding
resonance by using the harmonic response, thus the vibrations of hypoid gear may reduce.
Resonance is a vibration phenomenon that occurs at certain rotor speeds when the hypoid gear is
on the work. The influence of hypoid gear design resonance phenomenon is investigated by
Ansys software.
In this project, the three-dimension model of hypoid gear is modelled in CATIA and imported
into ANSYS software to perform static and dynamic analysis to analyze strength and dynamic
characteristics of hypoid gear and optimize if required.
7. DESIGN AND STRUCTURAL ANALYSIS OF HELICOPTER
ROTOR BLADE FOR DIFFERENT MATERIALS

ABSTRACT:
The blades of a helicopter are long, limited with a secondary perspective proportion. The
shapes of the blade are such-and-such minimizes drag starting with the tip of the vertices. They
hold a level about messiness that lessens those lift created at the corners, the place the wind
current may be speediest also vortex era. Blades of the rotor are large would commit out for
different materials, such as aluminum, composites, also steel. The helicopter rotor centre is
powered toward the engine, and the rotor blades would connect to the centre. The movement of
sharpened steel is regulated toward the helicopter rotor framework.

Those fundamental rotor sharpened steel influenced toward the wind stream for
revolution about sharpened steel and the impact of aeromechanic energy and radial energy
applying will be sharpened steel need to been completely acknowledged. The changing qualities
dissection from claiming rotor edge is principally included in the vibration control.

The goal will should figure the common recurrence furthermore operating recurrence for
rotor edge may be modulating the individual’s frequencies also avoiding thunder in rotational
speed, in this way, the vibrations of the helicopter might diminish.

In this project, the three-dimension model of helicopter rotor blade is modeled in NX-
CAD and imported into ANSYS software to analyze the strength, and dynamic characteristics of
rotor blade have been developed. The static strength and the dynamic characteristics about rotor
blade have been analyzed with ANSYS software for different materials (aluminum alloy and
composite materials). Throughout those contemplate of changing trademark analysis, those
impact of aeromechanic energy What's more radial energy applying with sharpened steel need to
been completely viewed.
8. DESIGN AND ANALYSIS OF ENGINE BLOCK

ABSTRACT:
A cylinder block is an integrated structure comprising the cylinder(s) of a reciprocating
engine and often some or all of their associated surrounding structures The various main parts of
an engine (such as cylinder(s), cylinder head(s), coolant passages, intake and exhaust passages,
and crankcase) are conceptually distinct, and these concepts can all be instantiated as discrete
pieces that are bolted together. The purpose of the engine block is to support the components of
the engine. Additionally, the engine block transfers heat from friction to the atmosphere and
engine coolant.
From carburetor or fuel injector (fuel and air mixture) is supplied to cylinders of the
engine. The fuel and air mixture are injected at high pressure into cylinders of the engine. Due to
this applied pressure on the cylinder, the cylinder undergoes some deformation and produce
stresses in the cylinder. With respect to stresses, Weight is also important factor in automobile
industries, due to heavy weight of engine block, power consumption is high.

In this paper, a research on static and dynamic behavior of a diesel engine block is carried
out in Finite Element Method (FEM) for grey cast iron. Stresses, Natural frequencies and Modal
shapes are obtained by FEM calculation. Besides, based on the results, the stress positions on this
block are identified to reduce the weight of engine, model is modified. Analysis is carried on
modified model for grey cast iron. NX-CAD software is used for 3d modeling of engine block
and ansys software is used for analysis of engine block.
9.DESIGN AND STRUCTURAL ANALYSIS OF PISTON RING USING FINITE
ELEMENT ANALYSIS

ABSTRACT

Mesh development technology is very important topic in now a days. These mesh can estimates
the material’s safe conditions whenever that material under loading conditions. After checking of
safe conditions analyst send that material design to manufacturing department. In manufacturing
department process plan is develop by production engineer. Process planning is a production
organization activity that transforms a product design into a set of instruction (Machine tool
setup etc.) to manufacture market part or produced economically and competitively. Process
planning activities basically include the following: interpretation of product design data,
selection of machining processes, selection of cutting tools, selection of machine tools,
determination of setup requirements, sequencing of operations, determination of the production
tolerances, determination of the cutting conditions, design of jigs and fixtures, calculation of
process times, tool path planning & NC program generation, generation of process route sheets
etc.

The aerospace component used in this project is a piston ring which is used in rockets.
These piston rings are used to release the rocket due to the pressure release in the chamber.
These piston rings are in cylindrical-shape that forms the movable seal in a cylinder. The
explosive force of combustion is exerted upon the surface of the piston ring. Due to this force the
ring deforms and stresses will be created.

In this paper we have done the 3D modeling of the piston ring and finite element analysis
was done to observe the deflections and stresses on the piston ring. Efforts are made to identify
the high stress locations and changes are made to reduce these stresses . Design of piston ring
done by unigraphics software and meshing and static of part done through Ansys FEA software
and stress results obtained from ansys multiphysics. Also Aluminium material and steel material
properties applied to designed piston ring and best material proposed from them based on
percentage of resultant stresses.
10. STATIC & MODAL ANALYSIS OF COMPOSITE BRACKET ASSEMBLY

ABSTRACT:

In an automobile industry while designing the components, the most critical aspect
considered is the compactness and the weight of the component. According to the Newton’s 2
law of motion the energy required to accelerate the vehicle depends upon the mass of the
automobile.

In the structural point of view the automotive materials should have more strength to weight
ratio. One of the structural automotive vehicles and which are more in number are the mounting
brackets. The mounting brackets are meant for supporting the structural component and
electronic components such as batteries, seats, cabin, chassis, rear body and also it should
support the external load such as passengers. Since it is very much needed to reduce the weight
and therefore it is to be redesigned or optimized for minimum weight without sacrificing the
functionality. The most common material used for the structural components is structural steel.

Substituting composite structures for conventional metallic structures has many advantages
because of higher specific stiffness and strength of composite materials.

Analysis will be performed for static and modal. The most important factors that are
concentrated are stress distribution, deflection and natural frequencies sfor two materials. The
design structure is carried through Unigraphics software. The reviewed design is analyzed
through Ansys software.
11.DESIGN AND MODAL ANALYSIS OF MUFFLER GUARD
ABSTRACT
The muffler is engineered as an acoustic soundproofing device designed to reduce the loudness
of the sound pressure created by the engine by way of acoustic quieting. The majority of the
sound pressure produced by the engine is emanated out of the vehicle using the same piping used
by the silent exhaust gases absorbed by a series of passages and chambers lined with roving
fiberglass insulation and/or resonating chambers harmonically tuned to cause destructive
interference wherein opposite sound waves cancel each other out.

An unavoidable side effect of muffler use is an increase of back pressure which decreases engine
efficiency. This is because the engine exhaust must share the same complex exit pathway built
inside the muffler as the sound pressure that the muffler is designed to mitigate.

This project deals with design of muffler guard using Unigraphics software and modal analysis
to find natural frequencies and deformations induced in muffler these analyses are done in Ansys
simulation tool, various commands, modal analysis and material properties are studied in this
project.

Fig1:A muffler on a large diesel-powered truck


12.DESIGN AND THERMAL ANALYSIS OF DRUM BREAK

ABSTRACT

This study for observing and investigating the heat distribution occurs on Brake drum
within the braking system. The temperature changes on the brake drum during the deceleration
providing the head distribution. It is includes the temperature distribution on brake drum and
friction occurs due to the deceleration of cars. The distribution of temperature depends on the
various factors such as friction, surfaces roughness, speed, and others, As a matter of fact, a
severe brake application will create a thermal environment on the friction surface with high
surface temperature.

The execution of the analysis is done by using ANSYS software where it shows area that
have been affected by heat and area that free from distortions. This method is functional with
usage of temperature to calculate the heat development and distribution. The analysis
implementation has been done to a surface of related on brake drum in the braking system.
Unigraphics software is used for developing design of drum brake.
13.HEAT TRANSFER IN THE CYLINDER HEAD OF A TWO-STROKE
ENGINE

ABSTRACT

The importance of heat transfer in design of two stroke engine is important to make sure the engine will
perform to expectation during actual working conditions. For this a prediction is done on the various heat
distributions that might occur during a normal operation of the engine. The finite element model was
evolved with many boundary conditions that are predicted from theoretical studies. This is to see the
general heat transfer of the engine and whether or not the engine will withstand the thermal loads
occurring during the theoretical operation. Assumptions are made by approximating temperature to the
actual operating condition of the engine. Heat transfer was modeled with conduction and convection as
the main source of heat transfer and neglecting radiation. The values are to be verified when the actual
engine is operating with correct boundary conditions. It is hoped that the engine will not come to the
boundary applied as it is assumed very high compared to actual condition.

The aim of this project is thermal analysis of cylinder head was done and analyzed the temperature
distribution over the fin area. Two different types of materials were taken for analysis and they are .
Design of cylinder head was done through Unigraphics software and Ansys software is used for thermal
analysis of cylinder head.
14.DESIGN AND ANALYSIS OF A CONNECTING ROD OF A DIESEL
ENGINE

ABSTRACT

The automobile engine connecting rod is a high volume production, critical component. It
connects reciprocating piston to rotating crankshaft, transmitting the thrust of the piston to the
crankshaft. Every vehicle that uses an internal combustion engine requires at least one
connecting rod depending upon the number of cylinders in the engine.

Connecting rods for automotive applications are typically manufactured by forging from either
wrought steel or powdered metal. They could also be cast. However, castings could have blow-
holes which are detrimental from durability and fatigue points of view.

The main objective of this study was to explore weight and cost reduction opportunities for a
production forged steel connecting rod. This has entailed performing a detailed load analysis.
The most important factors that are concentrated are stress distribution and deflections.
Connecting rod is designed by Unigraphics software and Ansys software is used for analysis of
connecting rod.
15.DESIGN AND STRUCTURAL ANALYSIS OF TILLAGE
EQUIPMENT

ABSTRACT
Tillage is the agricultural preparation of soil by mechanical agitation of various types,
such as digging, stirring, and overturning. Primary tillage process tillage equipment loosens the
soil and mixes in fertiliser and plant material, resulting in soil with a rough texture. Secondly, the
tillage process, tillage equipment produces finer soil and in few cases shapes the rows, preparing
and arranging the seed bed as per the requirement. It also provides weed control from beginning
to the end the growing season during the total maturation of the farms, unless such weed control
is instead achieved with low-till or no-till methods involving herbicides. In the process of
cultivation tillage equipment under goes worst loading condition which reduces the life of the
equipment.

In this project, a detailed structural Analysis of the tillage equipment under the worst loading
condition was carried out. During the part of a project, a dynamic analysis of tillage equipment
was performed using finite element analysis package. The three dimensional model of the tillage
equipment shall be designed using NX-CAD. Then the 3-D model shall be imported into
ANSYS using the Parasolid format. The analysis can be evaluated in a dynamic condition. From
the analysis results,

Mode shapes and frequencies are documented by using FEA software.

Harmonic analysis is performed by providing the force i/p to determine amplitude v/s frequency,
and the graphs are marked.

Transient analysis is done by providing Impulse or Shock loads for determining Amplitude
w.r.To Time and the graphs are plotted.

In this project, we shall also find out the safety factor of tillage equipment. Finally, design
optimisation of the tillage equipment shall be done to increase the life of the tillage equipment
component. NX-CAD software shall be used for 3D modelling of the tillage equipment, and
ANSYS software shall be used to do the structural analysis of the tillage equipment.
16. FINITE ELEMENT ANALYSIS FOR STATIC AND DYNAMIC
BEHAVIOUR OF COMPOSITE SHAFT

ABSTRACT

Drive shaft has a major role in vehicle transmission system. It is a mechanical part which is used
to transfer power from engine to wheel. Almost all automobiles have transmission shafts. Drive
shafts, as power transmission tubing are used in many applications including cooling towers,
pump sets, aerospace, trucks and automobiles. In Front wheel drive (FWD) car, maximum power
is transmitted through drive shaft. This power transmission mainly depends on size of drive
shaft. The drive shaft is subjected to torsional stresses and bending stresses. To achieve more
reliability, less cost and high quality, the drive shaft should be with less weight and more
strength and stiffness. Because of this reason weight optimization of front wheel drive shaft
plays a major role in achieving these major goals like less cost, high quality and reliability.

This project deals with the design of front wheel drive shaft for maximum power transmitted
from FWD car. This project includes detailed finite element analysis of front wheel drive shaft
for torsional and bending loads. The project involves performing analysis for drive shaft with
conventional steel and composite (E-GLASS/EPOXY) materials . In this project, the design of
front wheel drive is done by theoretical formulas for steel and composite (E-GLASS/EPOXY)
materials for torsional and bending loads. Design of front wheel drive shaft is done in NX CAD
software and Ansys software is used for static analysis of front wheel drive shaft.
17. DESIGN OPTIMIZATION OF SWING JAW PLATE OF A JAW
CRUSHER USING FINITE ELEMENT ANALYSIS

Abstract:

Jaw crusher is a machine designed to reduce large solid particles of raw material into smaller
particles. Crushers are major size reduction equipment used in mechanical, metallurgical and
allied industries. They are available in various sizes and capacities ranging from 0.2 ton/hr to 50
ton/hr. They are classified based on different factors like product size and mechanism used.
Based on the mechanism used crushers are of three types namely Cone crusher, Jaw crusher and
Impact crusher. The mechanism of crushing is either by applying impact force, pressure or a
combination of both. The jaw crusher is primarily a compression crusher while the others operate
primarily by the application of impact.

The present project is aimed at design and analysis of swing jaw plate of a jaw crusher.
As the jaw crusher has lot of moving components, it is subjected to a lot of linear and random
vibrations as well. In this present project the design and analysis has been extended to static
loading to meet the industry requirement. Since the rock strength also vary depending on the
different quarry, the crushers cannot be selectively designed with low factors of safety.
Considering this design and analysis has been carried out by increasing the loading by 25 % in
this project.

During the part of project a static and dynamic analysis of swing jaw plate was
carried out using finite element analysis package. The 3 dimensional model of the swing jaw
plate shall be designed using NX-CAD. Then the 3-D model shall be imported into ANSYS using
the parasolid format. The analysis shall be performed in static condition. NX-CAD software shall
be used for 3D modeling of the jaw crusher and ANSYS software shall be used to do the finite
element analysis of the jaw crusher.
18.MODELING AND STRUCTURAL ANALYSIS OF HELICOPTER
LANDING STRUCTURE FOR DIFFERENT MATERIALS

ABSTRACT:

The landing strut is a structure that supports a helicopter on ground and allows it to take-off,
and land. In fact, landing strut design tends to have several interferences with the helicopter
structural design. Now a day the weight of landing strut has become an important factor. Efforts
are being made to reduce the weight of the helicopter and consequently increase the payload.
This paper presents an approach to optimize the design of landing strut of a Light Compact
Helicopter (LCH) made of Carbon Fibre Composite Material adopted from Aerospace
Specification Metals (ASM). First the structural behavior is tested using the structural analysis
when subjected to behavior constraints. Optimization process is carried out iteratively to
minimize thickness of landing strut which results in the minimum weight of landing strut.
Vonmises and deflections of landing strut and also proved that results given by the ANSYS and
Unigraphics software is used for developing design.
19.DESIGN AND STRUCTURAL ANALYSIS FOR AIR FRAME COMPONENT
USING MESH TECHNOLOGY PACKAGE

ABSTRACT

Nowadays rejection is a serious problem arising in every manufacturing industry. Due to


this reason the manufacturing industry is advancing into losses. There are many factors
responsible for Rejection and reworks, such as Human errors, machine errors, process
planning.Machining of thin-walled components has increasingly become a difficulty for
manufacturers. Advanced digital analyses have been developed by many researchers to model,
predict and reduce errors induced by machining processes. Moreover, today’s machining shop
floors, characterized by a large variety of products in small batch sizes, require flexible
simulation tools that can be quickly reconfigured. CAD/CAE systems play a vital role in design
optimization any component and helpful in reducing the rejections and reworks.

Missile component is that releases fire from fighter jet. A missile comprises of many components
or subsystems. Each of them are important in their own right and require considerable care and
expertise to design. The airframe is the structure that houses (holds) all the missile subsystems.
Whenever missile is in operating conditions the total weight of missile parts applied on airframe.
So here should take accurate design of airframe that should be light weight. The present
invention relates to systems and methods for controlling weight optimization. More specifically,
the present invention relates to systems and methods for weight optimization in missiles.

Current project is presented about developing 3D modeling of airframe using CAD tool and that
should be structural analyzed by using FEA packages. The main aim of project is structural
analysis of airframe done by light weight material that is Steel material. Light weight material is
produce accurate results in safe conditions of part whenever that is in loading conditions. In this
project design of aircraft is done using NX CAD (UNIGRAPHICS) tool and meshes generated
on airframe using ANSYS software for good results in stresses and also results of deflections and
stresses obtained in ANSYS software.
20.DESIGN AND ANALYSIS OF A VERTICAL AXIS WIND
TURBINE BLADE

ABSTRACT

One of the most important design parameters for cost-effective SB-VAWT is selection of blade
material. SB-VAWT blades must be produced at moderate cost for the resulting energy to be competitive
in price and the blade should last during the predicted lifetime (usually between 20 and 30 years). At
present, Aluminum blades fabricated by extrusion and bending are the most common type of VAWT
materials. The major problem with Aluminum alloy for wind turbine application is its poor fatigue
properties and its allowable stress levels in dynamic application decrease quite markedly at increasing
numbers of cyclic stress applications. Under this backdrop, an attempt has been made in my project to
investigate alternative materials as SB-VAWT blade material.

In my project, required properties of the SB-VAWT Blade Materials are first identified. Then
available prospective materials are shortlisted and assessed. Subsequently, comparisons are made between
the available materials based on their mechanical properties and costs. Finally, comparisons have been
made between the design features of a SB-VAWT with Aluminum and the alternative material blades
using one of the prospective airfoils. The results of the design analyses demonstrate the superiority of the
alternative blade material over conventionally used Aluminum. Structural and modal analyses have been
conducted using advanced finite element methods.

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