DA01

DESIGN, ANALYSIS AND ERGONOMIC STUDY OF A

WHEELCHAIR
Wheelchair system is one of the common vehicles used by handicap or sick people are limited in
its functions, such as it needs human force to move it. It is also can't be use for a long period as
the user tired in moving the chair using his or her own energy. Then, the other problem is the
existence wheel chair is also not really comfortable as the shape and its position also cannot be
fixing to the user's body in getting comfortable seat. This project concerned about the ergonomic
factor which is the important element of human factor engineering and consideration of
wheelchair design are proposed after overall the criteria is appropriate with this factor. In this
project, the priority requirement is to evaluate the human factor engineering of the existing wheel
chair. The ergonomic need to adequate in the study of designing objects to be better adapted to
the shape of the human body or to correct the user's posture. Wheelchair design could be
preventing the user from sitting in positions that may have a detrimental effect on the spine. The
ergonomic desirable design of wheelchair which offers an appropriate variable features and other
elements which can be changed by the user that need come out with a few designs and evaluate it
according to human factor engineering and material selection. Before redesign it, researcher need
conduct a market survey to collect necessary data to be include in the product.

The work seeks to design wheelchair seating systems that address these challenges in the
functionality of the wheelchair, and by so doing, improve the comfort and quality of life. The
objectives of this thesis are to:
1. Evaluate the existing wheel chair in terms of human factor engineering.
2. Redesign and analyze the product according to human factor engineering and material
selections.
3. Simulate the prototype of the product using Catia V5 and Ansys software.

Design Processes

Design is the process by which the needs of the customer or the marketplace are transformed into
a product satisfying these needs. It is usually carried out a designer or engineer but requires help
from other people in the company.
Design essentially is an exercise in problem solving. Typically, the design of a new product
consists of the following stages:

Figure 1: Product Design Process

DA02

DESIGN AND ANALYSIS OF GANTRY END OF ARM AND

INPUT CONVEYOR
Gantry is a continuous-path, Cartesian -coordinate robot constructed in a bridge shape that uses
rails to move along in a single horizontal axis or along either of two perpendicular horizontal
axes.

Features of Gantry system

Gantry carriage for horizontal movement (Y axis) is made of high grade Aluminum and
moves on hardened guide rods with rollers grease packed for life. This ensures low inertia

and faster response.

Gantry beam is made of Steel.
Gantry beam is supported suitably on stands.
Drive to Gantry carriage is through steel chord reinforced polyurethane belt through

precision backlash free gear box and servo motor.

Vertical Axis beam is made of Aluminum profiles and moves on hardened guide rods

with rollers (grease packed for life) fixed on the Gantry carriage.
Drive to vertical axis is from a servo motor through back lash free reduction gearbox and

rack and pinion.

Lubrication to the rack and pinion is through a Lubrication Pot.
All the servo motors are brake motors to prevent over travel / fall of the motor in case of

Power failure
Piping and wiring of both the axes is routed through IGUS make cable drag chains
Horizontal Axis (Y axis ) has a rapid speed of 150 m / min and vertical axis has a rapid
speed of 75 m / min

Objective

Design/modified the end of arm and Input conveyor to handle the Output platina shaft
component

With respect to the dimensions of the output platina shaft component suitable grippers are

selected.
End of arm is designed to grip two components one is to load the component and another

is to unload the component.

Conveyor is designed to load 90 components on it as per the customer requirement.
Static analysis to be performed to determine the displacements, strains, stresses, and
reaction forces under the effect of applied loads.

DA03
DESIGN AND STRUCTURAL ANALYSIS OF CNC VERTICAL
MILLING MACHINE BED

In this project, a machine bed is selected for the complete analysis for both static and dynamic
loads. Then investigation is carried out to reduce the weight of the machine bed without
deteriorating its structural rigidity and the accuracy of the machine tool by adding ribs at the
suitable locations. In this work, the 3D CAD model for the base line and the optimized design
has been created by using commercial 3D modeling software CATIA. The 3D FE model has
been generated using HYPERMESH. The analyses were carried out using ANSYS and Design
Optimization is done with the help of Optistruct. The results were shown with the help of graphs
to analyze the effect of weight reduction on the structural integrity of the machine bed before and
after the weight reduction and conclusions were drawn about the optimized design.

DA04
DESIGN AND ANALYSIS OF CYLINDER AND CYLINDER
HEAD OF 4-STROKE SI ENGINE FOR WEIGHT REDUCTION

The project deals with design of cylinder & cylinder head with air cooling system for 4 strokes 4
cylinder SI engine. The main objective of design is to reduce weight to power ratio & will result
in producing high specific power. The authors have proposed preliminary design cylinder &
cylinder head of a horizontally opposed SI engine, which develops 120 BHP and posses the
maximum rotational speed of 6000rpm. Four stroke opposed engine is inherently well balanced
due to opposite location of moving masses and also it provides efficient air cooling. For the
requirement of weight reduction the material selected for design of cylinder and cylinder head is
Aluminum alloy that is LM-13. The cylinder bore coating using NIKASIL coating was done to
improve strength of cylinder with minimum weight..

DA05
DESIGN AND ANALYSIS OF TWO WHEELERS WHEEL WITH
THE REPLACEMENT OF ALLUMINIUM ALLOY

PEEK is an established material that is used in a variety of applications. PEEK has replaced
metals like Aluminum and brass for cost and weight saving reasons as well as metallic
reactions. It is also the one polymer that can meet the needs of more demanding applications
where very high or low temperatures or chemical resistance are key operational parameters
PEEK is an ideal replacement for Aluminum alloy as well as other types of metal tubing, and
even glass for weight reduction, comparable strength/mass, chemical resistance, hardness, and
low extractable. PEEK is particularly useful in the automobile industry for its weight. In an
application where 2 grams can make a difference and weight is directly correlated to fuel cost,
light weight PEEK is superior material matches aluminum in mechanical properties, and is more
resistant to fluids. In this project work the entire wheel design of two wheeler was chosen and
analyzed by applying different load and redesign the wheel again to minimize the deformation
and material will be changed from aluminum to PEEK(polyether ether ketone )The following
materials were chosen:Aluminum Alloy
PEEK(Polyether etherketone)
PEEK with 30% Glass fiber
PEEK-90 HMF 20
PEEK-90 HMF 40
Wheel design of two wheeler is made by using Catia and Analysis has been done by Ansys 14
software to determine the various stresses, strain and fatigue life of the wheel. The software has
helped us really to achieve our goal. As the whole analysis is done by the means of software
therefore result and observation are trustworthy and meet with our expectation.

DA06
DESIGN AND WEIGHT OPTIMIZATION OF CRANKCASE OF
A RECIPROCATING COMPRESSOR

Compressors are used in manufacturing household refrigerators, air-conditioners and heat pumps
etc. Most of the household refrigerators use hermetically sealed reciprocating compressor.
Reciprocating compressors are usually a piston-cylinder type of pump. The main parts include
a cylinder, piston, connecting rod, crankshaft, cylinder head and valves. The basic function of the
compressor in refrigerators is to move the refrigerant from the evaporator to condenser at a
temperature and pressure, at which it will be cooled giving its latent heat and changing back to
liquid.
The crankcase is the central structure of the reciprocating compressor, and supports practically
all the internal components of the compressor. The main function of the crankcase is to provide
sufficient stiffness for the compression mechanism to run adequately. Another function of the
crankcase is to act as stopper, absorbing any shocks that may occur during compressor
transportation. In this paper 3D model of crankcase is developed with the help of existing
reciprocating compressor. Finite element analysis is performed on the crankcase and efforts are
made to reduce the weight of the crankcase from the results of FEA. Catia software is
exhaustively used to model the crankcase and simulation results on stress and deformation
evaluated with the help of Ansys software.

DA07
MODELING AND ANALYSIS OF 2-STAGE REDUCTION GEAR
BOX

A reduction gear box is part of a mechanical system of gears and shafts used to reduce the
rotational speed of the input shaft to a slower rotational speed of the output shaft. This reduction
in output speed helps to increase the torque of a system. Reduction gears are widely used in
power transmission devices to reduce the high rotational speeds.
Gears have wide variety of applications. Gears are the most important component in power
transmission system. The gears generally fail when tooth stress exceeds the safe limit. It is
essential to determine the maximum stress that a gear tooth is subjected to, under a specified
loading. To prevent from failure Analysis is carried on gears.
The present work is directed towards the modeling of 2-stage reduction gear box with its
components like helical gears, pinions, integral shaft bearings and housing in a 3D cad tool
called SOLIDWORKS 2014sp1. This work investigates the characteristics of an involute helical
gear system mainly focused on bending stresses using solid works simulation. The analytical
study is conducted by using Lewis formula. The Study is conducted by varying the face width to
find the bending stress of helical gear. Finally It is observed that the maximum bending stress
decreases with increasing the face width of the gear. This study shows the complex design
problem of helical gear and required superior software skills for modeling and analysis.

DA08
DESIGN AND ANALYSIS OF CONNECTING ROD FOR
4 - STROKE PETROL ENGINE BY USING FINITE ELEMENT ANALYSIS

The connecting rod is the mediating member between the piston and the
Crankshaft. Its main function is to convert the reciprocating motion of the
piston into rotary motion of the crank. This project describes about a real
time problem of using Cast Iron connecting rod in 4 stroke motorbike its
modeling and analysis and optimization of connecting rod. Here, the
connecting rod is replaced by various materials like stainless steel,
aluminium, C70 steel and also a design change by inducing truss member is
suggested. The connecting rod is modeled using CATIA software for both
existing solid and modified truss designs. Boundary conditions are applied to
the models after finishing the pre processing work in ANSYS 14.0 software.
The best combination of parameters like Von misses stress and strain,
Deformation, Factor of safety, fatigue and life cycle calculation, bi-axiality
indication for two wheeler piston were done in ANSYS 14.0 software. This
project also tends to optimize the design by calculating weight and stiffness
for various materialistic designs by using the output values of mass and
volume of the connecting rod which will also be obtained from the software.
The project will be presenting the best design for future reference.

DA09

DESIGN AND ANALYSIS OF CRANE HOOK WITH DIFFERENT

MATERIAL
In this project the design of the hook is done by analytical method and design is done for the
different materials like forged steel and high tensile steel. After the analytical meth-od design and
modeling of hook is done in modeling soft-ware (solid edge) .The modeling is done using the
design calculation from the modeling the analysis of hook is done in FEA software
(ANSYS).This result lead us to the determination of stress in existing model. By predicting the
stress concentration area, the hook working life increase and re-duce the failure stress.
Crane hooks are highly liable components and are always subjected to failure due to
accumulation of large amount of stresses which can eventually lead to its failure. Crane hooks
are the components which are generally used to elevate the heavy load in industries and
constructional sites. A crane is a machine, equipped with a hoist, wire ropes or chains and
sheaves used to lift and move heavy material. Cranes are mostly employed in transport,
construction and manufacturing industry. Overhead crane, mobile crane, tower crane, telescopic
crane, gantry crane, deck crane, jib crane, loader crane are some of the commonly used cranes. A
crane hook is a device used for grabbing and lifting up the loads by means of a crane. It is
basically a hoisting fixture designed to engage a ring or link of a lifting chain or the pin of a
shackle or cable socket. Crane hooks with trapezoidal, circular, rectangular and triangular cross
section are commonly used. So, it must be designed and manufactured to deliver maximum
performance without failure.

DA10

DESIGN AND STRUCTURAL ANALYSIS OF A V12 ENGINE BY

USING DIFFERENT MATERIALS
A V12 engine often just called a V12 is an internal combustion engine with 12 cylinders. The
engine has six cylinders on each side called banks. The two banks form a "V" shaped angle. In
most engines, the two banks are at a 60 angle to each other. All twelve pistons turn a common
crankshaft. It can be powered by different types of fuels, including gasoline, diesel and natural
gas. A V12 engine does not need balance shafts. A V12 angled at 45, 60, 120, or 180 from
each other has even firing and is smoother than a straight-6. This provides a smooth running
engine for a luxury car. In a racing car, the engine can be made much lighter. This makes the
engine more responsive and smoother. In a large heavy-duty engine, a V12 can run slower and
prolonging engine life.
The main objective of the project is how to develop the prototype of V 12 engine assembly using
CAD tool Catia. This Engine assembly consists major components they are Piston, Connecting
Rod Assembly, crank Shaft, Cylinder head, Cam Shaft, Valves, crank case, oil tank and spark
plug with required dimensions. The components which are developed in catia are also analyzed
in it using simulation tool. The thermal analysis of piston, crank shaft, cam shaft and valve is
performed for 800k thermal loading and the results of temperature distribution of the
components are shown. Finally the thermal analysis results of the components are compared and
the best suited material is selected.

DA11

DESIGN AND ANALYSIS OF DISC BRAKE ROTOR FOR A TWO

WHEELER
A transient analysis for the thermo elastic contact problem of the disk brakes with heat
generation is performed using the finite element analysis. To analyze the thermo elastic
phenomenon occurring in the disk brakes, the occupied heat conduction and elastic equations are
solved with contact problems. The numerical simulation for the thermo elastic behavior of disk
brake is obtained in the repeated brake condition. The computational results are presented for the
distribution of heat flux and temperature on each friction surface between the contacting bodies.
Also, thermo elastic instability (TIE) phenomenon (the unstable growth of contact pressure and
temperature) is investigated in the present study, and the influence of the material properties on
the thermo elastic behaviors (the maximum temperature on the friction surfaces) is investigated
to facilitate the conceptual design of the disk brake system. Based on these numerical results, the
thermo elastic behaviors of the carbon-carbon composites with excellent mechanical properties
are also discussed.

DA12

STRUCTURAL ANALYSIS FOR FRAME OF A MACHINE

TOOL-EDM USING CAE TOOLS
The Machine Tool industry aims for high precision and repeatability while it is in operation. The
quality of the machine tool, in fact, is determined on this count. The structural components in the
machine tool play a vital role in helping to achieve consistent performance. The damping for the
vibrations, load-bearing capacity for the over-hung members, the stable alignment between the
mating parts forming links and for the components experiencing dynamic/ rotation movement in
the given pair.
The model of this EDM machine under review is now undergoing changes to the structure. The
new design needs to be reviewed in the light of structural strength while subjecting the
components/ sub-assembly to Analysis using CAE. The geometry of the machine frame/
structure is amenable to the usage of 3D modeling. The design of the structure would necessitate
knowledge of the fundamentals for Machine Design. The information like weight of the structure
and the relative position with respect to other elements of the machine tool can be readily offered
by the three dimensional CAD interface. Although the physical design can be done using the
facilities and/or the faculties above, the assessment of the geometry for conformance to the
conditions specified (test conditions) could be done through the utilization of a suitable tool
Software for Analysis in the domain of Structural Analysis.

DA13

DESIGN AND ANALYSIS OF A SHOCK ABSORBER

A suspension system or shock absorber is a mechanical device designed to smooth out or
damp shock impulse, and dissipate kinetic energy. The shock absorbers duty is to absorb or
dissipate energy. In a vehicle, it reduces the effect of traveling over rough ground, leading to
improved ride quality, and increase in comfort due to substantially reduced amplitude of
disturbances. When a vehicle is traveling on a level road and the wheels strike a bump, the spring
is compressed quickly. The compressed spring will attempt to return to its normal loaded length
and, in so doing, will rebound past its normal height, causing the body to be lifted. The weight of
the vehicle will then push the spring down below its normal loaded height. This, in turn, causes
the spring to rebound again. This bouncing process is repeated over and over, a little less each
time, until the up-and-down movement finally stops. If bouncing is allowed to go uncontrolled, it
will not only cause an uncomfortable ride but will make handling of the vehicle very difficult.
The design of spring in suspension system is very important. In this project a shock absorber is
designed and a 3D model is created using Pro/Engineer. The model is also changed by changing
the thickness of the spring. Structural analysis and modal analysis are done on the shock absorber
by varying material for spring, Spring Steel and Beryllium Copper. The analysis is done by
considering loads, bike weight, single person and 2 persons. Structural analysis is done to
validate the strength and modal analysis is done to determine the displacements for different
frequencies for number of modes. Comparison is done for two materials to verify best material
for spring in Shock absorber. Modeling is done in Pro/ENGINEER and analysis is done in
ANSYS. Pro/ENGINEER is the standard in 3D product design, featuring industry-leading
productivity tools that promote best practices in design.ANSYS is general-purpose finite element
analysis (FEA) software package. Finite Element Analysis is a numerical method of
deconstructing a complex system into very small pieces (of user-designated size) called
elements.

DA14

DESIGN AND ANALYSIS OF VERTICAL AXIS WIND TURBINE

A combined savonius and darrieus vertical axis wind turbine would have many advantages over
an individual savonius or darrieus rotor. A savonius produces high torque which would be useful
in self-starting and darrieus rotor having a high tip speed ratio useful for electrical generation.
However research on combined savonius and darrieus rotors is very scarce. This developed a two
bucket savonius rotor and placed it on the central shaft of a traditional darrieus. Though the tip
speed ratio is a still a little low for use as an electrical generator, the research demonstrated a
simple way to enable a darrieus VAWT to be self-starting and achieve higher efficiencies.
Historically VAWTs cost more to operate and maintain than HAWTs Finally, traditional Darrieus
rotors are not self-starting under most of wind conditions and manufacture of their blades is a
challenge because of the complex shape which adds expense to the turbine. However, evidence
shows that a Darrieus turbine using fixed geometry symmetrical airfoils can self-start in the field
during atmospheric gusting it was suggested that using a Darrieus blade together with a Savonius
blade has better performance than using them individually according to self-start ability and
efficiency of the turbine. Using a counter rotating wind turbine with a freely rotating generator
can produce higher amounts of power than common wind generators.

DA15
DESIGN AND ANALYSIS OF VERTICAL LIFT BRIDGE

Our project is on the analysis of vertical lift bridge. We are designing the model of the bridge
using CATIA software and imported it to ANSYS for doing analysis. Due to complex geometry
and loading conditions, analysis and design of vertical lift bridge include many simplifying
assumptions. Although good approximations can be made in the development of analytical
models, it is not possible to make exact simulations of the loading, structural geometry, and
boundary (support) conditions of a structure. Therefore, it is difficult to develop an exact model
of even a new structure. For existing structures, construction tolerances, deterioration of seals,
and wear at support points are factors that further alter loading and structural conditions. To
ensure that a safe structural design is produced, assumptions on loading and structural
characteristics can generally be conservative. So that a reliable assessment can be made, it is
desirable to identify the unknown quantities (loading, boundary conditions, etc.) with sufficient
accuracy.
Experimental systems can measure the actual response of a structure subjected to various
loading. However, with most systems only a few selected points on a structure can be monitored.
An optimum evaluation system would incorporate both analytical and experimental techniques.
An analytical model of such a system can be systematically modified until it simulates structural
behavior observed under experimental conditions. This type of evaluation system is currently
under development in this study.
We are considering the deck and truss of the bridge for our analysis because to eliminate the
complexity of the project. We are considering the bridge as a fixed beam and the load to be a
uniformly distributed load and calculated total deformation, maximum stresses and strains.

DA16

DESIGN, MODELLING AND ANALYSIS OF A 3 STAGE

EPICYCLIC PLANETARY REDUCTION GEAR UNIT OF A
FLIGHT VEHICLE
In this project, a three stage epicyclic planetary reduction gear unit is designed to meet
the output specifications. All the components are modelled in CATIA to check the assembly and
the interference. The modelled components are used for analysis to check for their strength.
Heavy vehicles consists of four control surfaces for steering and stabilization purpose. The
control surface are to be rotated depending upon the requirement of the system. This rotation of
control
system is achieved through actuators. Actuators can be of different types. They are pneumatic,
hydraulic and electro-mechanical. In the present project, we use electro mechanical actuators.
Electro-mechanical actuators basically consists of prime mover, motor and transmission
mechanism. This transmission system can be screw type or gears type. In this project, we use
gear type of transmission system, which is designed depending upon the requirement. Generally
motor rotates with very high speed and low torque. But the final requirement is low speed and
high torque. This is achieved by connecting a reduction gear unit which reduces the speed and
increases the torque. Planetary gear is one of the epicyclic gear, which is a gear system consisting
of One or more outer gears, or planet gears, revolving about a central, or sun gear. And it can be
wildly used in industry, such as printing lathe, automation assembly, and semiconductor
equipment and automation system since its commercial value. Our project is aimed to build a 3D
model of multiple layers of planetary gear by Using Catia software.