Final Report

JSS MAHAVIDYAPEETHA
SRI JAYACHAMARAJENDRA COLLEGE OF ENGINEERING,

Mysore- 570006
(An autonomous institute affiliated to Vishvesvaraya technological university,
Belgaum-590018)
DEPARTMENT OF MECHANICAL ENGINEERING
A Project report on
DESIGN AND FABRICATION OF

MOULD FOR FATIGUE TEST
SPECIMEN
Submitted in partial fulfilment of the requirements for the
award of bachelors degree in Mechanical Engineering
BY
Subramanya.Parande
4JC10ME058
M.Noor Khalandar
4JC10ME033
Akash.S.Biradar
4JC10ME002
UNDER THE GUIDANCE OF

1
DR. N.D.JAWALI,
Professor ,
Department of Mechanical Engineering,
SJCE, Mysore
ABSTRACT
This project deals with design and fabrication of the mould or tool for the
preparation of a circular polymer composite specimen which will be subjected to
fatigue test. The very importance of this project lies in its ability to replace metallic
elements with that of polymers. Now a days research is being done to apply new
materials for the existing components. Therefore there are several methods by which
this can be obtained, one such method is slush moulding. The process of tool making
involves a series of direct stages, which completes in a proper planning and proper
thinking and co-ordination must result in a successful tool. This project report has been
prepared with an outlook to import optimum, information about a tool in a more easily
grasping in a short span of time. We have made an earnest attempt to cover the entire
process of tool making process considering the various steps involved to make the
mould in a safe and fastest method and a high degree of accuracy in its functional
aspects while manufacturing the tool within the specified cost and time.
2013-2014
JSS MAHAVIDYAPEETHA
SRI JAYACHAMARAJENDRA COLLEGE OF ENGINEERING,
Mysore- 570006
(An autonomous institute affiliated to Vishvesvaraya technological university,
Belgaum-590018)
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the project work entitled DESIGN AND FABRICATION OF
MOULD FOR FATIGUE TEST SPECIMEN is a bonafide record of the work carried out
by Subramanya.Parande (4JC10ME059), Marur Noor Khalandar (4JC10ME033) and
Akash.S.Biradar (4JC10ME002) students of final year B.E., in partial fulfilment of the
requirements for the award of the degree of B.E in Mechanical Engineering, during the year
2013-2014.
GUIDE
PRINCIPAL
Dr. N.D.JAWALI
Professor,
Dr. Syed Shakeeb Ur Rehman,

SJCE, Mysore
Dept. of Mechanical Engineering

EXAMINERS
NAME
I.
...
SIGNATURE
.......
3
II. .
III.
..
DECLARATION
We, the students of final semester B.E in Mechanical
Engineering, Sri Jayachamarejendra College of Engineering,
Mysore, hereby declare that dissertation entitled DESIGN
AND FABRICATION OF MOULD FOR FATIGUE TEST
SPECIMEN, has been carried out under the guidance of
Dr.N.D.JAWALI,
Professor,
Department
of
Mechanical
Engineering, SJCE, Mysore and Submitted in partial fulfilment of
the requirements for the award of Bachelor of Engineering
degree
in
Mechanical
Engineering
by
Visvesvaraya
Technological University, Belgaum during the academic year
2013-14. Further the matter presented in this dissertation has
not been submitted previously by us or anybody for the award
of any degree or diploma to any other university.
Subramanya.Par
ande (4JC10ME058)
Marur Noor
Khalandar (4JC10ME033)
Akash.S.Biradar (4JC10ME002)
Place: Mysore
Date:
ACKNOLEDGEMENTS
We take this opportunity to express our sincere gratitude and remain
deeply indebted to those who helped us to finish this project work successfully.
Firstly, we would like to thank our Principal, Dr. Syed Shakeeb Ur

Rehman for his co-operation and encouragement during the course of my
project.
We remain indebted to our project guide Dr.N.D.JAWALI,

Professor, Department of Mechanical Engineering for
supervising and supporting me throughout this project.
It is a pleasure to express our deep sense of gratitude and profound thanks

to Mr.Manjunath for guiding us in the right direction.
We extend my sincere thanks to Mr.Arun for guiding us in the right

direction from the beginning of this project without which our successful
completion of the project work would have been difficult.
Su
bramanya.Parande
Marur Noor Khalandar
Akash.S.Biradar
CONTENTS
ABSTRACT
.
CERTIFICATE
.
DECLARATION
..
ACKNOWLEDGEMENTS
LIST OF FIGURES.
LIST OF TABLES .
CHAPTER 1: INTRODUCTION
CHAPTER 3: LITERATURE REVIEW
CHAPTER 4: OUTLINE OF STUDY
8
CHAPTER 6: RESULTS AND DISCUSSIONS

CHAPTER 7: CONCLUSION
CHAPTER 8: SCOPE FOR FUTURE WORK
LIST OF FIGURES
Figure
no.
1.1
1.3
4.1
Figure description
Page
no.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
LIST OF TABLES
Table
no.
Table Name
Page
no.
4.1
4.2
4.3
4.4
4.5
5.1
CHAPTER 1
INTRODUCTION
Any product to be manufactured invariably requires tools. Tool design and
development is a specialized and critical area. Since tool is an aid for mass production it
should be accurate and economical for successful life of a product.
In 1860s there was invention of the first plastic, cellulose nitrate .plastics are
hydrocarbons consisting of large chains of carbon and hydrogen atoms. Plastics dont
resemble each other either in appearance or characteristics.
There are two types of plastics:
1. Thermo set plastics
2. Thermo plastics
Thermoplastics
There are a wide range of thermoplastics, some that are rigid and some that aree
extremely flexible.
The molecules of thermoplastics are in lines or long chains with very few
entanglements. When heat is applied the molecules move apart, which increases the
distance between them, causing them to become untangled. This allows them to become
soft when heated so that they can be bent into all sorts of shapes.
When they are left to cool the chains of molecules cool, take their former position and
the plastic becomes stiff and hard again. The process of heating, shaping, reheating and
reforming can be repeated many times.
10
Long chain molecules
Thermo set plastics

The molecules of thermosetting plastics are heavily cross-linked. They form a rigid
molecular structure.
The molecules in thermoplastics sit end-to-end and side-by-side.
Although they soften when heated the first time, which allows them to be shaped
theybecome permanently stiff and solid and cannot be reshaped.
Thermoplastics remain rigid and non-flexible even at high temperatures. Polyester
resin and urea formaldehyde are examples of thermosetting plastics.
11
Cross-linked molecules
MOULDING
Molding of plastics comprises of forming an article to the desired shape by the
application of heat and pressure to the moulding component in a suitable mould and
hardening the material in the mould
TYPES OF PLASTIC MOULDING:Extrusion

The extrusion molding process begins with raw plastic such as pellets, powder
or beads. A hopper feeds the plastic into a revolving chamber. The chamber,
12
called an extruder, turns and melts the plastic. The melted plastic is forced out
of a die and becomes the shape of the finished product. The item is dropped
onto a conveyer belt, where it is cooled with water, cut and finished. Items
Products made by extrusion include sheets, film and pipes.
Injection Moulding
Injection moulding uses the same principle as extrusion. The raw plastic is fed
from a hopper to a melting chamber. However, instead of being forced out of a
die, the melted plastic is forced into a cold mould under high pressure. Once the
mould cools and solidifies, the product is cleaned and finished. Products made
by injection moulding include butter containers, bottle caps, toys and lawn
furniture.
Blow Moulding
Blow moulding is a process that uses a blowing method after extrusion or
injection moulding. Extrusion blowing uses a die that creates a heated plastic
tube with a chilled mould around it. Compressed air is blown through the tube
to force the plastic to conform to the shape of the inside of the tube. This allows
manufactures to create a continuous, uniformly melted, hollow shape without
having to attach separate injection-moulded parts. Injection blowing still uses an
injection mould, but instead of a finished product, the mould is an intermediate
form that is heated to be blown into a final shape in a different cold mould.
Compression Moulding
Compression moulding is the process of taking a pre-specified volume of plastic
material, putting it into a mould, and then using another mould to flatten or
compress the plastic into the previous mould. The process can be automated or
manual, and it can use either thermoplastics or thermosets.
Thermoforming
13
Thermoforming is the process of taking heated film and softening it to conform

to a mould shape. The film is not melted, but heated so that it can be soft
enough to be pressed into a mould. The manufacturer forces the plastic into the
desired shape through the use of high pressure, a vacuum or a plug. After the
finished product has cooled, it is sheared from the mould and scraps are
recycled to be put in new film.
Slush Moulding
Slush moulding is a closely related but somewhat different technique to dip
moulding and is used for the production of flexible and semi-rigid mouldings
where a detailed surface finish is required on the outside of the moulding.
Whereas a male former or tool is used to produce a dip moulding reproducing
the tool surface on the inside of the moulding, slush moulding enables you to
produce the fine detail effects on the outside of the moulding using a hollow
female mould or tool, in effect, the reverse of dip moulding.
The mould is pre-heated then filled with liquid material to a pre-determined

level, subsequently the curing process starts resulting in the desired wall
thickness. The remaining liquid material is then decanted and final curing takes
place, after which the tool is cooled and the finished moulding is stripped from
the mould.
The process needs either, fabricated steel, cast or machined aluminium tools and
it is because such tooling in inexpensive, by comparison with, for instance,
injection or blow moulding, that small and medium quantities can be moulded
allowing considerable design freedom. Typical applications are toys, dolls
heads, manikin models, containers, balls, large gaiters and many others.
14
OBJECTIVE OF THE PROJECT:To fabricate the mould for the preparation of plastisol specimens using
slush moulding technique.
CHAPTER 2
COMPANY PROFILE
CHAPTER 3
15
LITERATURE REVIEW
Y.A.Khalid,S.A.Mutahser,V.B.Sahari,A.M.S.Hamouda [1]
Obtained results by increasing the number of layers
would enhance the fatigue strength of composite tube
up to 40%.
Sagar R D, Sachin G M,Jayant P G,Neelesh D K [2]
obtained result that replacement of conventional drive
shaft result in reduction in weight of automobile.
Mohammed Reza k, Amin Paykani,Aidin Akbarzadeh[3]

have concluded that a one piece composite driveshaft
is considered to be replaced a two piece steel
driveshaft.
3.1 CONCEPTS REFERRED
16
Fundamentals of Turbo-machinery, Types of fans and their applications,

Impeller design,Different types of Housing design for fans and blowers.
Modelling Aid Fundamentals of CAD, Geometric Dimensioning &Tolerance
(GD&T), Types of Projections, etc.
Analysis Aid - Stress-Strain relationship for ductile and brittle materials,
Theories of Failure, Fundamentals of Finite Element Analysis (FEA) like:
Types of Contacts, stiffness matrix, Meshing Element types and sizing,
Mapping of Mesh, etc.
3.2SOFTWARES USED
3.2.1 SOLIDWORKS 2012 PREMIUM
Solidworks Premium is a comprehensive 3D design solution that
possesses powerful motion simulation, design validation, ECAD/MCAD
collaboration, reverse engineering and advanced wire and pipe routing
functionality. This CAD software offers an easy to use set of tools for 3D
and 2D design of any system. It has the capability to create shape based
and operation based features. Various viewing options in the software
provide a better way for the study of 3D model. Editing options available
are very much user friendly.
3.2.2 ANSYS14.5 Workbench
It is a framework upon which advanced engineering simulation
technology are built. Its project schematic view ties together the entire
simulation process, and guides to even more complex multi physics
analyses with drag and drop simplicity. It provides bidirectional CAD
connectivity, powerful and highly automated meshing, project level
update mechanism, pervasive parameter management and integrated
optimization tools. This enables simulation driven product development. It
includes CAD integration technology in CAD neutral CAE integration
environment. This integration has named selection manager. This feature
is used to create custom attributes within CAD systems that can be
directly used in ANSYS application for modelling, meshing and analysis.
17
ANSYS Workbench is an integration of Design Modeller and ANSYS

Mechanical/Structural module. These modules together in a single window
provide a better way of organising the analysis tree.
3.2.3 Design Modeler
It is a gateway to geometry handling for analysis.Built on the Para
solid geometric modeling kernel, the geometry engine is robust and
conforms to industry standards. It has connections to all major CAD
systems, which allows seamless transfer of existing data including
parameters. Any CAD model usually includes details that are not needed
for simulation such as logos and other small features. Simulating such a
fully detailed model increases the solver run time. It is efficient to spend a
short time removing these details to reduce the total run time by hours or
days. ANSYS Design Modeler product is fully parametric. This is combined
with parametric meshing and parametric solver setup within the ANSYS
Workbench platform so that the same geometry can be used for multiple
design variations.
3.2.4ANSYS Mechanical
Mesh generation is one of the most critical aspects of engineering
simulation. Too many elements results in long solver runs, and too few
leads to inaccurate results. In ANSYS Mechanical, the meshing technology
provides a means to balance these requirements and obtain the right
mesh for each simulation in the most automated way possible. ANSYS
Meshing technology has been built on the strengths of standalone, class
leading meshing tools. The strongest aspects of these separate tools have
been brought together in a single environment to produce some of the
most powerful meshing available. ANSYS Structural simulation doesnt
require very high quality meshes and smoothness of size changes; rather
it calls for an optimized meshing and mapping of elements. ANSYS
meshings physics preference setting ensures the right mesh for the
simulation. Highly automated meshing environment makes it simple to
generate tetrahedraltype of meshing. Easy user controls make mesh
18
settings
very
straight
forward.
Mesh
connectivity
is
maintained
automatically.
CHAPTER 4
OUTLINE OF STUDY
4.1 Design of the Study
I.
The existing model of the mixed flow fan is modelled part by part in
Solidworks Premium 2012. The assembly is created in Assembly
workbench of the software.
II.
A .step file of the assembly is saved which is later imported to ANSYS

workbench.
III.
This model is taken into ANSYS workbench and analysed with

designed loading conditions.
IV.
The same model is applied with the new loading conditions, analysed
and interpreted to suit the design requirements.
V.
If the component is found to satisfy the design requirements, the

same model is approved. Otherwise, suitable changes are made to
profile or to the features where the attention is required in
Solidworks and a .step file is created.
VI.
Steps 3 and 4 are repeated for the modified model.
VII.
Afinal model satisfying all the design requirements is obtained and

reported.
4.2DATA COLLECTION
19
4.2.1 Loading Conditions

Table 4.1: Specified Loading details for the Study
Acceleration
Component
Type of load
Old loading
conditions
New loading
conditions
Pressure
in MPa
direction
Cap loads in N
+20g
+20g
+20g
0.5
1608.50
+20g
+20g
+20g
3217.00
Face 1
Face 2
1036.3
0
2072.6
1
4.2.2 Material Information

4.2.2.1 ALUMINIUM ALLOY BS1490 LM-25-TF
LM25 is mainly used where good mechanical properties are required
in castings of shape or dimensions requiring an alloy of excellent
castability in order to achieve the desired standard of soundness. The
alloy is also used where resistance to corrosion is an important
consideration, particularly where high strength is also required. TF
represents Fully Heat Treated condition.
Table 4.2: Mechanical properties of Aluminium Alloy BS1490
Youngs Modulus
71 GPa
Poissons Ratio
Density
0.33
2680 kg/m3
Tensile Yield Strength
200 MPa
Tensile Ultimate Strength
230 MPa
Elongation
01%
20
4.2.2.2 STAINLESS STEEL BS970 416-S-21

Martensitic (Magnetic) in nature, can be hardened and tempered to
give improved tensile strength.
Typical applications include spindles,
Rotor cores and shafts, fasteners, valves, surgical instruments, cutlery.

Table 4.3: Mechanical properties of Stainless Steel BS970
Youngs Modulus
196.5 GPa
Poissons Ratio
0.25
Density
7999.5 kg/m3
413.7 MPa
689.5 MPa
Elongation
13 15 %
4.2.2.3 STRUCTURAL STEEL

This material is found in Engineering Material Library of
ANSYS
14.5 engineering data workbench. It is default recommended by ANSYS to

use this material if material data is not given. Here this material is applied
to all the nuts, bolts, washers and screws found in the assembly.
Table 4.4: Mechanical properties of Structural Steel
Youngs Modulus
200 GPa
Poissons Ratio
0.30
Density
7850 kg/m3
250 MPa
460 MPa
4.2.3 Main parts of the assembly:

Table 4.5: Material and quantity information of important components of
the Fan Assembly
Sl.
Component Name
No.
Number
of Items
Material Standard
21
Casing
Al alloy BS1490
Guide Vane Assembly
Al alloy BS1490
Impeller
Al alloy BS1490
Main Shaft
Stainless Steel BS970
Shaft Key
Rotor Core Assembly
Case Electronics
Al alloy BS1490
End Cover
Al alloy BS1490
End Plate Assembly
Al alloy BS1490
10
PCB
Al alloy BS1490
11
Bearing Liner
12
Radial Ball Bearing
--
Structural Steel
Magnet Carrier & Mould

13
Assembly
14
Location Ring
All nuts, bolts ,screws &
15
washers
22
Fig 4.1: Cross-sectional view of the Fan Assembly
CHAPTER 5
ANALYSIS PROCEDURE
23
5.1DESIGN CONSIDERATIONS:
Recommended Modelling Software- SOLIDWORKS PREMIUM 2012
Recommended Analysis Software ANSYS Workbench 14.5
The assembly is to be analysed only under Static Structural System of
the ANSYS workbench. Modal and Random Vibration System analysis is
beyond the scope of this project.
Material Facts are not to be changed for any of the part belonging to
the assembly.
The system is to be studied under Worst-case environments.

During Meshing in ANSYS, the sizing of elements and mappingof
specific regions (if required) should be optimised and should be kept
the same throughout the Iterative study.
5.2 PART MODELLING AND ASSEMBLY:
Draft copies of all the parts which make up the Mixed Flow Fan are
obtained.
Part modelling of all the components is carried out in Solidworks
Premium Part Workstation and saved as individual .sldprt files.
Part modelling of standard Bolts, nuts, washers and screw are avoided
as these components can be directly included into the assembly
workstation through the Solidworks Toolbox Library.
Further, the central Main Shaft is first taken into the Assembly
Workstation of the Solidworks and is made fixed.

One after the other, all the individual part files are launched to
assembly
workstation.
Bottom - up assembly method is followed as it is handy and easier.

The parts are mated and constrained as specified in the Final
Assembly Draft given as input to the project. If interference is found
between parts, the parts are checked for accurate dimensions ion draft
and modified.
24
Bolts, nuts, washers and screw are brought from toolbox library and
added wherever necessary with the given specifications.
The fix feature applied to centre shaft is removed and is all degrees of
freedom (DOF) are constrained except rotation about its longitudinal
axis.
Casing and Guide Vane Assembly pats are made fixed as these are only
two parts which are firmly bolted to other systems or duct.
5.3STUDY OF THE 3-D MODEL:
Straighteni
ng vanes
Fig5.1: 3D cross-sectional view of the assembly showcasing air flow
This 3D model of mixed flow inline duct fan was examined. Parts of
the Fan assembly are as shown in Fig. 5.1& Fig 4.1. Air enters the Impeller
eyethrough opening in the casing due to low pressure created by rotation
of the impeller. Air is diverted as shown in Fig 5.1, further it is straightened
by 12 Guide vanes which are present in the Guide vane assembly. This air
is ducted out for coolingessential drive components,densely packed
25
electronic equipment, or systems having high or variable resistance such

as filters and small electric actuator or drive motors
5.4 Housing of the Fan Assembly:
Casing
Guide
vane
Assembly
Fig 5.2: casing and Guide vane Assembly parts make upthe Housingfor
the fan assembly
The analysis study is mainly concentrated on two parts of the Fan
assembly namely- CASING and GUIDE VANE ASSEMBLY. This is because the
entire Fan assembly is connected to flange or duct through eighthole
locations of casing and guide vane assembly. As the dissertation deals
with only Structural analysis, it is a requirement of study report to be
focussed on main load bearing/supporting part(s).
5.5
Analysis Considerations and Assumptions:

26
5.5.1 Environment conditions

The system is analysed onworst-case environment conditions,
in which
The system has to be analysed with giving Acceleration loading

individually in all the 3-directions along with other loads.
Fixed support regions are reduced to four fastening regions which

are inGuide Vane Assembly part.
5.5.2 Point Mass

As discussed in item 5.4, though the study is focussed on housing of
the Fan assembly, it becomes inappropriate to completely neglectthe
effect of internal components on results & conclusions. Hence, a
calculated point mass is added at the centroid of the support faces of
housing to simulate the net effect of the internal components.
Point mass is: 0.31654 kg
Fig 5.3point mass shown as a lump at the centroid of the support

faces (red faces)
5.5.3 Bonded Contact

27
It is clear from the assembly that the type of connection between

Casing and Guide Vane Assembly is through Hexagonal socket Head
cap Screw ISO 4762 M3 x 10. The analysis requirement is to neglect
the stress at this fastener location and make it as a bonded contact for
easy, time valuing simulations and results.
Fig 5.4 Red and Blue coloured faces depicting bonded contact
regions
5.6 Meshing
5.6.1 Element size
Auto generated Meshing size in ANSYS APDL Workbench is found to
be too coarse. Hence, a Body Sizing of element size 3mm is given to
the housing.
28
Fig 5.5 Entire Housing is Body sized to 3 mm element size

5.6.2 Mapped Meshing
Haphazard, Irregular meshes are the reasons for generation of
Singular stress. Hence, a mapping is given to regions of greater
concerns.
Fig 5.6 Purple coloured faces showing Mapped Mesh regions

5.7 Supports
As per the environment conditions discussed in 5.5.1, the four
mounting holes on the Guide vane Assembly are constrained in all
degrees of freedom. This makes it as Fixed Support.
29
Fig 5.7 Four mounting holes of Guide Vane Assembly are made Fixed
Supports
5.8Loading
5.8.1 Acceleration Loads
Simulation runs are carried out by applying acceleration loads
in only one direction at a time.
30
Fig 5.8 Housing loaded with 20g acceleration load in X, Y & Z-axes
5.8.2 Pressure loading

Pressure is applied on all the 44 inner faces where the air
comes in contact with as shown in Fig 5.9.
31
Fig 5.9 Pressure Load applied on all the inner faces of the Housing
5.8.3 Cap loading
A component or vessel when subjected to pressure loading,
experiences stresses in all directions. The normal stresses resulting from
the pressure loading are the functions of diameter of the component.
These normal stresses are called Cap stresses or cap loads.
Mathematical formula to calculate Cap load is:
F = P*A
Where,
F ------ Force (N)
P ------ Pressure (N/mm2 or MPa)
A ------ Area (mm2)
Table 5.1:Details of Cap loading
INLET
OUTLET
Pressure
32
Diame
Area
ter
(mm2
(MPa)
(mm)
Diameter
Force
(N)
(mm)
D1
D2
Area
Force
(mm2)
(N)
1608.
0.5
64
1.0
3217
1036.
50
74.1
53.5
2072.6
30
3217.
2072.
50
61
Fig 5.10 Faces on which Cap loads are acted upon

5.9 Interpretation
The housing after simulation is analysed according to Maximum
Principal Stress Theory. This is because of two reasons The material of housing as given in table 4.2.3 is Aluminium Alloy
BS1490. From its Mechanical properties table, it is clear that the
material behaves as brittle material since its Elongation is < 5%.
The process of manufacturing the part is by Sand casting method.
Castings are normally considered as brittle.
5.10 Casting Factor and Factor of Safety
Casting Factor:
To negotiate for the defects in casting process, the Ultimate Tensile
Strength of the material is reduce by certain units, which is called
33
CASTING FACTOR. This ensures the design to be safe even under

operating extremities.
For Aluminium casting, Casting Factor is taken as 0.85
Factor of safety (FoS):
Factor of Safety is a ratio of absolute strength (structural capacity)
to allowable or permissible load. This is a measure of the reliability of a
particular design.
Mathematically,
FoS=
YieldUltimate strength
Allowable stress
In this case Factor of Safety is taken as 2.

5.11 Design Strength of the Housing:
After considering the Casting Factor and Factor of Safety, the
permissible stress or design strength of the housing is
Allowable Stress=
UltimateTensile StrengthCasting Factor

Factor of Safety
230 0.85
2
Allowable Stress = 97.75 N/mm2
34
CHAPTER 6
RESULTS AND DISCUSSION
6.1 SIMULATION RESULTSOF ORIGINAL CASING FOR OLD LOADING

CONDITIONS
6.1.1 Acceleration loading in X-axis
35
Fig 6.1 Total deformation plots
36
The Maximum Principal Stress observed on the Guide vaneis a singular

stress. Hence ignored.
Fig 6.2 Stress distribution on the housingaccording to Maximum principal
stress
37
The Maximum Principal Stress of 97.243 MPa is observed on the

Casing as shown.
Fig 6.3 Stress distribution on Casing according to Maximum Principal
Stress
38
6.1.2 Acceleration loading in Y-axis:
39
Fig 6.4 Total Deformation Plots
The Maximum Principal Stress observed on the Guide vane is a singular stress.
Hence ignored.

stress
40
The Maximum Principal Stress of 96.743 MPa is observed on the Casing

as shown.
Stress
41
6.1.3 Acceleration loading in Z-axis:
42
The Maximum Principal Stress observed on the Guide vane is a singular

stress
43

Casing as shown.
Fig6.9 Stress distribution on Casing according to Maximum Principal
Stress
6.1.4 Inference
The given housing is simulated with old loading conditions .It is
evident from the deformation and Maximum Principal Stress plots of
content 6.1.1, 6.1.2, 6.1.3 that the housing designis within the allowable
or design strength of 97.75 N/mm2.
44
6.2 SIMULATION RESULTS OF ORIGINAL CASING WITH NEW

LOADING CONDITIONS
6.2.1 Acceleration loading in X-axis:
45
Fig 6.10 Total deformation Plots
46
Hence ignored.
Fig 6.11 Stress distribution ploton the housingaccording to Maximum
principal stress

as shown.
47
Fig 6.12Stress distribution on Casing according to Maximum Principal

Stress
6.2.2 Acceleration loading in Y-axis:
48
Fig 6.13 Total deformation Plot
49
Henceignored.
Fig 6.14 Stress distributionon the housingaccording to Maximum principal

stress

as shown.
50

Stress
6.2.3 Acceleration loading in Z-axis
51
52
Hence ignored.

stress
53

as shown.
Stress
6.2.4 Inference:
In Chapter 6.2, the housing is loaded as per the new design
specification and calculations. It is clearly evident from the plots of
content 6.2.1, 6.2.2, 6.2.3, that the given housing design fails at NECK or
FILLET region of Casing part. Hence, a suitable change is to be made and
simulated with the same loading conditions.
54
6.3 STUDY OF THE GIVEN CASING
Fig 6.19 Dimensional details of the given Casing part

Since the Maximum stress region is found to be the Fillet region, it is
possible to obtain a better design by changing the fillet size. The fillet size
of the given casing is found to be 2.50mm.
55
6.4 DESCRIPTION OF MODIFIED CASING

The Dimensional detail of the given Casing is carefully studied.
Considering the inlet flange dimension of 3mm and also by an intuitive
approach to design, it is advisable to increase the fillet size to 3.00mm.
Hence, the fillet size is changed to 3.00 mm and the housing is
simulated.
Fig 6.20 Dimensional details of the modified Casing part
56
6.5 SIMULATION RESULTS OF MODIFIED CASING FOR NEW

LOADING CONDITIONS
57
58
Hence ignored.

stress
The Maximum Principal Stress of 143.35 MPa is observed on the Casing as

shown.
59

Stress
6.5.2 Acceleration loading in Y-axis
60
61

stress
62

as shown.
Stress
63
6.5.3 Acceleration loading in Z-axis:

64


stress
65

as shown.
Stress
6.5.4 Inference:
In Chapter 6.3, Simulation results of modified Casing are obtained. It
is clearly evident from the Deformation and Stress plots in content 6.3.1,
6.3.2, 6.3.3, that the dimensional change of the fillet has affected the
results. A maximum stress of 143.35 N/mm 2 is observed at the fillet region
when the acceleration loading in in X-axis. Since the allowable or design
stress is 97.75N/mm2, there is a necessity of altering the dimensions in
the fillet region of the Casing.
66
6.6 DESCRIPTION OF THE GEOMETRY OF 2ND MODIFED CASING
FLANGE
SLOPE
Fig 6.30 Dimensional details of the 2nd modified casing

It is observed from Chapter 6.3, that an increase in fillet size by just
0.5mm has reduced the stress in the region by approximately 50 N/mm 2.
Hence, for the next iteration, increasing the fillet size is considered.
However, if a fillet size increase to 3.50 mm is employed, the results
of the design may be come under safe limits, but, there comes violation of
SMOOTH TRANSITION between flange and slope as flange thickness is 3
mm and the slope thickness 3.33 mm. Hence, a fillet size obtained by
averaging slope and flange thickness is taken, which is 3.20 mm.
67
Additional to this, a step of 1 mm thickness as show in Fig 6.36 is

added to compensate for the reduced increment level of fillet size.
6.7 SIMULATION RESULTS OF FINAL CASING WITH NEW LOADING
CONDITIONS
68
69

stress

as shown.
70

Stress
6.7.2 Acceleration loading in Y-axis
71
72

stress

as shown.
73

Stress
6.7.3 Acceleration loading in Z-axis
74
75
Hence ignored.
stress

Casing as shown.
76

Stress
6.7.4 Inference:
Deformation and Maximum Principal Stress Plots for the latest
modified Casing is obtained and studied. It is evident from the results that
Maximum Stress is obtained for Acceleration loading in X-axis and its
value is 72.391 N/mm2.
Since this value of Maximum Stress is below the Allowable or Design
stress of 97.75 N/mm2, the housing is said to be adhering to all the design
consideration and specifications.
CHAPTER 7
CONCLUSION
The objective of the project work is to study the Housing of a Mixed
Fan assembly under the new Military Design specifications, and to ensure
the housing adheres to the design requirements and considerations.
The given assembly was simulated in Static Structural system of
ANSYS Workbench and it was found that the Casing part of housing was
breaking down for the new loading conditions. Hence, suitable geometrical
design changes are made to the concerned regionand simulated in an
Iterative manner.
77
Thefinal design shown in Fig 6.30 is found to satisfy all the design
requirements and considerations.
CHAPTER 8
SCOPE FOR FUTURE WORK
This Project work is constrained to only Static Structural analysis.
The Modal analysis, Harmonic response analysis and Random Vibration
analysis is out of the scope this project.The Fan Assembly can be studied
under the above listed systems of the ANSYS Workbench by obtaining
suitable design data and study pattern information. However, all
discussions, inferences and conclusions made in this Projectmust be
78
considered while doing future study or while making changes to the

geometry of the housing when fresh requirements are dealt with.
BIBLIOGRAPHY
1. Gere J. M. And Goodno B.J., Mechanics of Materials, Cengage
Learning, 7th Edition, 2012.
2. John May, British Standard Specification for Wrought steel for
mechanical and allied engineering purposes, Powertrain Ltd.,
February 20, 2002.
3.
4.
79
5.
6.
7. http://www.hadleighcastings.com/uploads/LM25%20Alloy
%20Detail.pdf
80

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JSS MAHAVIDYAPEETHA

SRI JAYACHAMARAJENDRA COLLEGE OF ENGINEERING,

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN AND FABRICATION OF

UNDER THE GUIDANCE OF

DEPARTMENT OF MECHANICAL ENGINEERING

Dr. Syed Shakeeb Ur Rehman,

Dept. of Mechanical Engineering

Firstly, we would like to thank our Principal, Dr. Syed Shakeeb Ur

We remain indebted to our project guide Dr.N.D.JAWALI,

It is a pleasure to express our deep sense of gratitude and profound thanks

We extend my sincere thanks to Mr.Arun for guiding us in the right

CHAPTER 6: RESULTS AND DISCUSSIONS

Long chain molecules

Thermo set plastics

TYPES OF PLASTIC MOULDING:Extrusion

Thermoforming is the process of taking heated film and softening it to conform

The mould is pre-heated then filled with liquid material to a pre-determined

Mohammed Reza k, Amin Paykani,Aidin Akbarzadeh[3]

3.1 CONCEPTS REFERRED

Fundamentals of Turbo-machinery, Types of fans and their applications,

ANSYS Workbench is an integration of Design Modeller and ANSYS

A .step file of the assembly is saved which is later imported to ANSYS

This model is taken into ANSYS workbench and analysed with

If the component is found to satisfy the design requirements, the

Steps 3 and 4 are repeated for the modified model.

Afinal model satisfying all the design requirements is obtained and

4.2.1 Loading Conditions

4.2.2 Material Information

Tensile Yield Strength

Tensile Ultimate Strength

4.2.2.2 STAINLESS STEEL BS970 416-S-21

Typical applications include spindles,

Rotor cores and shafts, fasteners, valves, surgical instruments, cutlery.

Tensile Yield Strength

Tensile Ultimate Strength

4.2.2.3 STRUCTURAL STEEL

14.5 engineering data workbench. It is default recommended by ANSYS to

Tensile Yield Strength

Tensile Ultimate Strength

4.2.3 Main parts of the assembly:

Guide Vane Assembly

Stainless Steel BS970

Stainless Steel BS970

Rotor Core Assembly

Stainless Steel BS970

End Plate Assembly

Stainless Steel BS970

Radial Ball Bearing

Stainless Steel BS970

Stainless Steel BS970

Stainless Steel BS970

Magnet Carrier & Mould

Fig 4.1: Cross-sectional view of the Fan Assembly

The system is to be studied under Worst-case environments.

Workstation of the Solidworks and is made fixed.

Bottom - up assembly method is followed as it is handy and easier.

electronic equipment, or systems having high or variable resistance such

5.4 Housing of the Fan Assembly:

Analysis Considerations and Assumptions:

5.5.1 Environment conditions

The system has to be analysed with giving Acceleration loading

Fixed support regions are reduced to four fastening regions which

5.5.2 Point Mass