# 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
Phil Palmer
OBJECTIVES

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

   Evaluate stress and deformation resulting

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

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…

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

   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
   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
   Maximum shear
stress of 6.180e5
Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection

   Max. Deflection of
7.296×10-6 m
ANALYSIS (Solution Phase)
Principal Stresses
   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
   Maximum shear
stress of 6.180e6
Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection

   Max. Deflection of
7.296×10-5 m
ANALYSIS (Solution Phase)
Principal Stresses
   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
   Maximum
shear stress of
6.199e5 Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection

   Max. Deflection of
2.083×10-5 m
ANALYSIS (Solution Phase)
Principal Stresses
   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
   Maximum shear
stress of
6.199e6 Pa

   Passed
ANALYSIS (Solution Phase)
Maximum Deflection

   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.
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
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
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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