Bishop Steering Project

ME450 Computer-Aided Engineering Analysis Department of Mechanical Engineering, IUPUI Instructor: Dr. Nema May 2, 2005 By: Samir Yassine & Molly Meeks
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Objective
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To analyze Bishop Steering Rack Fixture using ANSYS To apply FEA knowledge gained throughout semester to previous senior design project

Introduction
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The Customer: Bishop Steering Technology markets, supplies and supports leading edge steering technology worldwide. The Game: Design adjustable, precision fixturing system for CNC machining of variable ratio teeth in steering racks.

Introduction
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Main Design Criteria

Rack

deflects or shifts <= .1 microns under tool load Mount 3 racks in work area 2 DOF, 5 travel, high precision

Theory
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Fairly simple volume Tetrahedral Brick Element type. Quadratic displacement behavior that is suited for modeling irregular meshes SOLID92 - Element defined by 10 nodes and 3 DOF at each node. - useful when importing drawings from various CAD/CAM systems.

Model Analysis
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Bishop Smart rack Rack was modeled in Pro-E Brick element, Solid92 Properties:
- E = 206842.7 MPa - Poissons Ratio = 0.3 - density = 7861.93 Kg/m3.
Meshed smart rack in ANSYS
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Analysis
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Rack was meshed using the smart size Mesh The size level was set to 10(coarse)

- Coarser mesh, would be solvable under

the design and loading conditions
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Displacement load of 0 was applied to the lower sides of the rack

Analysis
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Matlab program was written and executed to estimate the forces applied by the jaws.

0 0.1 0.2 0.3 0.4 0.5 0.6

Force, Upper Lip (N)

0.747 0.71 0.69 0.69 0.722 0.822 1.158

Force, Lower Lip (N)

0.463 0.389 0.315 0.235 0.134 -0.025 -0.413

Forces applied by vise teeth with corresponding friction coefficients

Analysis
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These forces were applied as pressure loads that are experienced by the rack The pressure load that the rack experiences from the tool force was applied (162.46 N Max)

The LS was solved, and then graphed and the displacement vector sum graph yielded results

Results
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After solving, the deformed and undeformed shapes were obtained

The maximum displacement under tool and jaw load was found to be = 0.0286 * 10-6 m This is well under the design specification of not more than 0.1 * 10-6 m

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Impact Statement
Steering racks are produced for many vehicle manufacturers around the country and the world n Main component of the rack-and-pinion steering system n High precision racks provide greater accuracy and better control of the vehicle at high speed
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Conclusions
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The maximum displacement under given loads was found to be = 0.0286 * 10-6 m. This result is well under the design specification of not more than 0.1 * 10-6 m

ANSYS proves to be a terrific tool in the hands of engineers that saves precious time and provides accurate results.

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Acknowledgments
Dr. Nema n Dr. Chen n Design group: Josh Peters, Scott Strickler, Andrew White
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