Bicycle Wrench Presentation by nikeborome

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									                                          ME 450 Project
                                                4/30/2007




                ME450: Computer-Aided Engineering
                              Analysis
               Department of Mechanical Engineering,
                                IUPUI
                Instructor: Dr. Koshrow Nematollahi




Bicycle Wrench Analysis
       Danny Compton
        Adam Douglas
         Phil Palmer
OBJECTIVES

   Perform finite element analysis of a Bicycle
    Wrench using ANSYS Workbench.

   Evaluate stress and deformation resulting
    from applied loads and constraints.

   Evaluate that this design is satisfactory and
    will not fail during use.
INTRODUCTION
   The Bicycle Wrench design blueprint
INTRODUCTION CONTINUED…

   The Bicycle Wrench design intent is to
    simplify the model orientation of the
    wrench using FEA Analysis. To know
    what the best material for production
    of wrenches should be used.




      Example   +   Pro E Model   =   FEA Analysis
INTRODUCTION CONTINUED…

 Normal   loading conditions were
  chosen to be 10N and 100N being
  applied to the wrench.
 Analyzing these forces on the
  wrench is very beneficial when
  determining what material to use,
  and how much force that material
  will with stand.
Theoretical Background
 10-node tetrahedral elements were
  used to mesh the model.
 Well suited for modeling models with
  curved boundaries and are very accurate.
BOUNDARIES

   Use of ANSYS Workbench

   Maximum number of nodes = 550 nodes

   Total number of elements = 54

   Use of properties of Aluminum

   Use of properties of Steel
BOUNDARIES

   Properties of Aluminum / Steel

          Steel             Aluminum 6061
ANALYSIS (Pre-Processing)

   The part was modeled in Pro/Engineer and imported
    into ANSYS Workbench

   All parts were assigned properties of Aluminum
    6061 / Steel alloy construction

   Factor of safety of 3 was applied on the part, telling
    us our tensile strengths, from which we could
    determine if the wrench would fail.

   Fixed support was assigned at the left edge of the
    wrench

   Design was statically analyzed
ANALYSIS (Pre-Processing)
Meshing

   The imported model was meshed and 550
    nodes were obtained

   Using ANSYS Workbench, parts were
    suppressed


                             550 nodes
ANALYSIS - Final Model

             LOADING                    MESH




   10N & 100N force applied on        550 Nodes
    right edge of wrench
   Fixed support applied at left      54 Elements
    edge
ANALYSIS (Solution Phase)

   Principal Stresses

   Shear Stresses

   Maximum Deformation
ANALYSIS (Solution Phase)
Principal Stresses
Steel – Loading (10N)
   Maximum
    Principal stress of
    1.189e6 Pa

   Yield stress for
    Steel alloy is
    2.5e8 Pa

   Maximum
    stresses occur
    where the part
    potentially failed
ANALYSIS (Solution Phase)
Shear Stresses
Steel – Loading (10N)
   Maximum shear
    stress of 6.180e5
    Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection
Steel – Loading (10N)




   Max. Deflection of
    7.296×10-6 m
ANALYSIS (Solution Phase)
Principal Stresses
Steel – Loading (100N)
   Maximum
    Principal stress of
    1.189e7 Pa

   Yield stress for
    Steel alloy is
    2.5e8 Pa
   Maximum
    stresses occur
    where the part
    potentially failed
ANALYSIS (Solution Phase)
Shear Stresses
Steel – Loading (100N)
   Maximum shear
    stress of 6.180e6
    Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection
Steel – Loading (100N)




   Max. Deflection of
    7.296×10-5 m
ANALYSIS (Solution Phase)
Principal Stresses
Aluminum 6061 – Loading (10N)
   Maximum
    Principal stress of
    1.187e6 Pa

   Yield stress for
    Aluminum alloy is
    1.15e8 Pa

   Maximum
    stresses occur
    where the part
    potential failed
ANALYSIS (Solution Phase)
Shear Stresses
Aluminum 6061 – Loading (10N)
   Maximum
    shear stress of
    6.199e5 Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection
Aluminum 6061 – Loading (10N)




   Max. Deflection of
    2.083×10-5 m
ANALYSIS (Solution Phase)
Principal Stresses
Aluminum 6061 – Loading (100N)
   Maximum
    Principal stress of
    1.187e7 Pa

   Yield stress for
    Aluminum alloy is
    1.15e8 Pa

   Maximum
    stresses occur
    where the part
    potential failed
ANALYSIS (Solution Phase)
Shear Stresses
Aluminum 6061 – Loading (100N)
   Maximum shear
    stress of
    6.199e6 Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection
Aluminum 6061 – Loading (100N)




   Max. Deflection of
    2.083×10-4 m
Impact Statement


   Through the use of finite element analysis on
    the bicycle wrench, we determined that both
    the 6061 Aluminum and structural steel
    propose no risk of structural failure in normal
    operating conditions.
Conclusion - Advantages of
Final Iteration

   Using the same properties for density and
    the volume given in ANSYS, we calculated
    the mass of the wrench for both steel and
    6061 aluminum:
    Volume            9.22E-05 m3
    Mass (steel)      0.723927 kg
    Mass (aluminum)   0.000249 kg
Conclusion - Advantages of
Final Iteration
   The cost difference of 6061 aluminum and
    structural steel can be seen below, which
    was used to calculate the cost per cubic
    foot of the material.

                           $ per ft3

        6061 Aluminum      1223.16

        Structural Steel   1101.60
Conclusion - Advantages
of Final Iteration
   Our final analysis for this wrench is that if the
    consumer is looking for a lighter weight tool,
    the aluminum would be the best choice. If
    strength and cost are more important to the
    consumer than the structural steel would be
    the best choice.
Bibliography


 ME 450 Course Text
 ANSYS Website www.ansys.com
 www.metalsdepot.com

								
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