Hyper Mesh Research Articles

Structure optimization and contact law study for transmission linkage of manipulator grasping fragile parts

According to the grasping requirements for fragile workpieces with cylindrical inner walls, a manipulator with internal bracing has been designed. The manipulator utilizes a constant-speed push cylinder to drive the linkage mechanism and accomplish the related works. Considering the fragile nature of the workpieces, reducing the impact velocity between the manipulator finger and the workpiece is a primary objective in the mechanism design. To achieve this, an optimization design is carried out, which maintains the overall average speed of the manipulator, while reducing the average speed only during the contact between the finger and the workpiece. The goal of optimization is to minimize the impact velocity at the contact point, using the linkage structure parameters as variables. The genetic algorithm (GA) is employed for the optimization process. The results show that optimization reduces the impact velocity at the contact point by 44.80%. To gain further insight into the influence of the process, a finite element model of a finger grasping a fragile object was created using joint modeling with the SolidWorks, Hyper Mesh, and LS-DYNA software. Simulations reveal that, after optimization, the maximum internal stress of three workpieces with thicknesses of 2.00 mm, 1.00 mm, and 0.50 mm was reduced by 47.42%, 41.53%, and 44.20%, respectively. To study the general law of the mechanical hand grasping fragile workpieces, the relationship between the cylinder driving speed and the impact speed is established. Based on the simulation results of maximum contact impact velocity, workpiece wall thickness, and maximum contact force, a prediction model of workpiece internal force is established using the Kriging prediction model theory. Additionally, the feasible range of grasping parameters under different wall thickness conditions is determined and discussed. The reliability of the designed structure is experimentally verified, providing valuable insights for ensuring the lifting work reliability of manipulators handling fragile workpieces.

Evaluate the effect of bone density variation on stress distribution at the bone-implant interface using numerical analysis.

The current study aims to comprehend how different bone densities affect stress distribution at the bone-implant interface. This will help understand the behaviour and help predict success rates of the implant planted in different bone densities. The process of implantation involves the removal of bone from a small portion of the jawbone to replace either a lost tooth or an infected one and an implant is inserted in the cavity made as a result. Now the extent of fixation due to osseointegration is largely dependent on the condition of the bone in terms of the density. Generally, the density of the bone is classified into four categories namely D1, D2, D3, and D4; with D1 being purely cortical and D4 having higher percentage of cancellous bordered by cortical bone. A bone model with a form closely resembling the actual bone was made using 3D CAD software and was meshed using Hyper Mesh. The model was subjected to an oblique load of 120 N at 70° to the vertical to replicate occlusal loading. A finite element static analysis was done using Abaqus software. The stress distribution contours at the bone-implant contact zone were studied closely to understand the changes as a result of the varying density. It was revealed that as the quantity of the cancellous bone increased from D1 to D4 the cortical peak stress levels dropped. The bone density and the corresponding change in the material characteristics was also responsible for the variation in the peak stress and displacement values.

Research on dynamic characteristics of cutter breaking frozen soil and optimal drum rotation speed of the new shaft tunneling machine

To improve the efficiency of frozen soil excavation, the new shaft tunneling machine was developed. The new shaft tunneling machine exerts pressure on the frozen soil through the cutter under the joint action of its own gravity, the drum rotational force and the inertia force, and the frozen soil is damaged. By unique way of breaking frozen soil to improve the efficiency of frozen soil excavation, the drum rotation speed is one of the factors affecting the performance of frozen soil excavation. This article applies SolidWorks software to establish the model of cutter breaking frozen soil, takes advantage of Hyper Mesh finite element software coupled with LS-DYNA solver to acquire the regular pattern of change in the force change, frozen soil stress–strain and specific energy of cutter crushing frozen soil, etc., which analyzes the destruction of frozen soil when the drum of the new shaft tunneling machine is rotating at the speed of 25–40 rpm. Combine with field test to investigate the mechanism of cutter breaking frozen soil under the optimal drum rotation speed. The investigation results demonstrate that: when frozen soil's self-bearing capacity is lower than the force of cutter, it breaks up and detaches from the soil body, and frozen soil undergoes tensile, compressive and shear damages. For this research, it is instructive for practical engineering.

Microstructure Image-Based Finite Element Methodology to Design Abradable Coatings for Aero Engines

Upgrading abradable or wearable coatings in the high-temperature zone of aero engines is advised to increase the efficiency and high-density power in gas turbine engines for military or commercial fixed-wing and rotary-wing aircraft. The development of these coated materials is also motivated by minimization of the number of failures in the blade, as well as increasing their resistance to wear and erosion. It is suggested that abradable coatings or seals be used to accomplish this goal. The space between the rotor and the shroud is minimized thanks to an abradable seal at the blade’s tip. Coatings that can withstand abrasion are often multiphase materials sprayed through thermal spray methods, and which consist of a metal matAzmeerix, oxide particles, and void space. The maintenance of an ideal blend of qualities, such as erosion resistance and hardness, during production determines a seal’s effectiveness. The objective of this research is to develop microstructure-based modelling methodology which will mimic the coating wear process and subsequently help in designing the abradable coating composition. Microstructure modelling, meshing, and wear analysis using many tools such as Fusion360, Hyper Mesh, and LS-Dyna, have been employed to develop an abradable coating model and perform wear analysis using a simulated rub rig test. The relation between percentage composition and morphology variations of metal, oxide, and voids to the output parameters such as hardness, abradability, and other mechanical properties is explored using simulated finite analysis models of real micrographic images of abradable coatings.

Simulasi Aliran Dingin Pada Mesin Pembakaran Internal

The dynamics of fluid flow in the engine combustion cylinder is very important for preparing the air-fuel mixture. Internal Combustion Engine models are built with the help of CATIAV5R20 software. The model is then imported into the HYPER MESH Finite Element preprocessing tool for splicing analysis. The model is then loaded into the finite Element breaker application. Using ANSYS FLUENT, the results are further processed. At various minimum valve lifts, cylinder flow dynamics is examined using FEA. For various crank angles, from 0° to 720°, plots of dynamic velocity and motion magnitudes are displayed. Finally, various crank angles and valve lift speeds are compared.

Bionic Mechanical Analysis of Dragonfly Wings: The Feasibility of Mesh Combination to Improve Structural Stiffness

The nodes of the object will show different degrees of deformation and displacement or even damage over time. The mesh structure is flexible and different mesh shapes and arrangements will affect the structural stiffness of the object. The unique structure of dragonfly wing veins allows the dragonfly to withstand pressures several times higher than itself and to fly freely. This study is based on dragonfly wing bionics to disassemble the structure of dragonfly wing vein geometry. And it aims to investigate the deflection under different geometries and three-dimensional spatial structures by using the drawing software Auto CAD to draw dragonfly sample graphics, the finite element software Hyper mesh to build the model and the solver OptiStruct to analyze the structure of wrinkling, arching deflection, z-direction maximum displacement, y-direction maximum rotation angle, combined displacement test under the different loads. The results show that: (1) The dragonfly wing vein mesh structure can enhance the stiffness under load. (2) In contrast, the displacement deformation of quadrilateral and combined hexagonal is smaller. (3) The structural stiffness of quadrilateral hexagon is enhanced as the height of wrinkling and arching increases. (4) The improvement of grid deflection with membrane structure is better than that without membrane structure. According to the above experimental results, the quadrilateral wrinkling and hexagonal arching structure has a significant improvement on the load bearing and deflection of the mesh, and has the potential to make structural optimization of the mesh series products, which is suitable for practical application and promotion.

Research on Lightweight Injection Molding (CAE) and Numerical Simulation Calculate of New Energy Vehicle

Abstract In this paper, the new energy automobile front-end frame of a factory is taken as the research object, the polypropylene plastic is used to replace the traditional sheet metal material, and the hyper mesh is used to load the front-end frame’s six loading loads, which are the locking limit tension and the cushion impact force, respectively, pedestrian impact strength, condenser support strength, radiator support strength, oil cooler support strength, ensure to achieve certain mechanical properties before production. The maximum warpage deformation is 1.023 mm by mold flow analysis with Moldflow. It does not meet the needs of manufacturers, so it is necessary to optimize the process parameters. We use the mold temperature, melt temperature, holding pressure, injection time, and holding time as test factors, and take the amount of warpage as the optimization goal. Then this paper uses the orthogonal test method to design the test plan and establishes 25 groups of 5-level 5-factor orthogonal tests. Moreover, the effect of the deformation on the warpage is analyzed. These are all to obtain the minimum warpage deformation and find the optimal combination of process parameters. Verification by numerical simulation shows that the warpage is reduced to 0.632 mm. By analyzing the range and variance, the combination of process parameters is optimized, and the warpage is effectively reduced. In the premise of satisfying mechanical properties, plastic instead of steel, to achieve a lightweight design. It provides correct theoretical guidance for setting the actual injection molding process parameters.

Durability Analysis in Seat Components based on Design Criteria

In this study, the suitability of the M1 class vehicle rear seat according to the ECE R17 luggage retention regulation has been examined. Strength and cost improvement studies were carried out on the seat corner component. The development studies for the seat to be tested according to the boundary and loading conditions specified by the ECE R17 regulation were created in the finite element method pre-processing software Hyper Mesh and the analysis was carried out in the RADIOSS solver. The design of the seat, which was determined by finite element analysis results, was verified by physical tests.

A Literature Review and Study on Design, Fabrication and Analysis of Tie Rods for Steering Mechanism

Abstract: Tie rods or Track rods are an integral part of vehicle’s steering system. Just as its name suggests a Tie rod ties vehicle’s steering rack to the steering arm. It is used to give direction to tires according to steering wheel movement. A tie rod assembly is attached to each end of the relay rod. The tie rod assembly consists of inner and outer tie rods that are usually connected through an adjusting sleeve. Tie rod may get fail due to varying forces and bumping of vehicle during steering. The forces from the steering are also considered during the static condition of car. Fatigue and buckling of Tie rod has been continuously a concern which may lead to structural failure if the resulting vibration and stresses are undesirable and excessive. Even if the stresses are less than yield they may fail under repeated loading. Considering this problem research work is aimed to assess buckling strength and compare buckling performance of Tie rod for different materials. In this first according to the condition basic cad geometry is designed using cad software and finite element model generated using Hyper Mesh. And then modal, static and transient dynamic analyses to obtain natural frequencies, displacement, stresses distributions in tie rod. For safe design of tie rod corrective actions and considerable modifications carried out and to validate the modified design of tie rod finite element analysis carried out.

Design and Analysis of Marine Propeller

This paper presents a comparison between propellers varying in design to evaluate their performance and efficiency. A propeller is a type of fan that transmits power by converting rotational motion into thrust. A pressure difference is produced between the forward and rear surfaces of airfoil shape blade and fluid is accelerated behind the blades which generates two forces, one along the longitudinal direction of ship which is the axial force called thrust force and tangential force which produce the required torque. As propeller has great influence on the propulsive performance of ship, propeller design is important technology for energy saving in ship propulsion. Generally, alloy of aluminium or bronze material are used for manufacturing of marine propeller. The propeller is a complex geometry which requires high end modelling software. The solid model of propeller is developed in HydroComp PropCad 2005 and SolidWorks 2019 and a tetrahedral mesh is generated for this model using HYPER MESH and simulation is carried out using SolidWorks. By considering all the study and benefits this model helps to find the optimum propeller for defined objectives. Based on optimized parameters the propellers performance is calculated by the simulation of designed model.

Three-Dimensional Finite Element Analysis for Stress Distribution During Intrusion and Retraction Using Orthodontic Mini-implants

Background and Objectives: the study was conducted to evaluate the levels of stress produced in and around implants when placed at different sites for retraction and intrusion of maxillary anteriors. The other objective was to evaluate stress levels produced at implant bone interface when mini implants were placed at different angulations at the same site. Materials and Methodology: Finite element model of the maxilla and maxillary dentition was constructed using the CT skull of subject used in the study. All the accessories used like mini-implants, stainless steel wire, coil springs etc were scanned separately for obtaining detailed anatomic features. The force was given between retraction hook and mini -implant using NITI closed coil spring for intrusion and retraction of maxillary anterior teeth. The basic mechanical factors i.e. the stresses developed in mini implant, the angle of insertion of the mini implant into the bone surface were analyzed. Finite Element model was generated by Hyper mesh 9.0 software. Analysis was carried out by using Ansys 12.1 software. Results and Conclusion: All the set objectives were accomplished at the end of the study which included complete closure of extraction space by retraction and intrusion in the models. The following conclusions were drawn: The least stress was seen on an implant at middle third, when inserted at an angle of 800 to the bone surface, with application of 50-100mg of intrusive force on anterior implant and 200 gms of retractive force on posterior implant.

Stress distribution in tooth supported removable partial denture fabricated using two different materials: A 3-dimensional finite element analysis

A suitable material and design plays an important role in the fabrication of a removable prosthesis. The distribution of forces plays a significant role in preservation of the remaining structures especially the abutment teeth. In this study 2 models were prepared using, computed tomography (CT Scan) and 3-Dimensional construction software; of Kennedy’s Class 3 partially edentulous situation. The models were classified based on the material used in fabrication of the prosthesis as; Model 1- Cobalt Chromium denture; Model 2-Thermoplastic Nylon dentures. The meshing of the models was done using hyper mesh 13 and, the contact and constraint conditions were defined for the analysis model. The material properties were incorporated and the stress analysis was done by applying an unidirectional force of 40 N per tooth on three posterior teeth. The analysis was done using ANSYS version15 and the results were analyzed. Model 1 (cobalt chromium) showed a maximum displacement of 0.00718 mm and maximum stress of 19.87 MPa, Model 2 (Thermoplastic nylon) showed the maximum displacement of 0.0094 mm and maximum stress was 29.97 MPa. Within the limitations of this study the stress evaluation on different prosthetic materials revealed that the areas of maximum stress were seen on the palatal slopes of the maxillary residual ridge and on the anterior abutment tooth (canine) in both models. However, the Cobalt-Chromium model showed significantly lesser stress as compared to the Thermoplastic nylon model.

Analysis of automotive car chair

This work aims to design a car seat and simulate its performance using different standard tests using finite element method (FEM). There are two main components: (1) design; and (2) FEM analyses. We build a generic automotive rear seat with the aid of the software CAD Catia V5. In this analysis, finite element simulations were performed. The software was the well-known finite element solver Hyper mesh and LS-Dyna. In order to verify the correct application of demands from the standard rules, stresses and moving data are obtained from the computer simulation of the seating system in order to make adjustments in the design, if necessary within the permitted limits. This tool allows the refinement of the geometry, materials and so on before production of the prototype to be achieved, thus reducing costs and developing time for the manufacturer.

Numerical and experimental analysis of torsional stress of traditional and modified steering yoke

Growing competition and inventions in the automobile sector calls for either the modification of available products or the replacement of the old ones by fresh and advanced types of material products. To conserve natural resources along with economizing energy, reducing weight has been the focal point of automobile makers in the current scenario. Due to the added luxury and safety features, the weight keeps on increasing, which in turn reduces fuel efficiency and the total performance of the automobile. Therefore, reducing the weight of the automobile is the prime need of the current automotive industry. Steering yoke is a critical component of a vehicle, which links the suspension and the steering system. The failure study of steering yoke assembly shows that about 71% of failure occurs in yoke part. This paper focuses on optimization of steering yoke by targeting uniformity of stress over the entire structure as an objective function, without compromising with required strength and stiffness of the structure. CAD model of steering yoke was prepared in CATIA. Hyper Mesh was used to prepare a finite element model with ABAQUS solver. Topology optimization with OptiStruct solver, one of the modules of Hyper Works, was utilized for optimization of material. Modifications were done to the geometrical model and was iterated till achieving satisfactory results. It was observed that the stresses were uniformly distributed over the entire structure and maximum stress in the yoke was reduced by 22.8%. The mass of the modified yoke was also reduced by 22.5%. The FEA results of modified yoke were verified by comparing it with torsion experiment to validate the model.

Design, Analysis and Optimization of Engine Mounting Bracket for SAE Supra Car Using Finite Element Analysis

<div class="section abstract"><div class="htmlview paragraph">The power train components of vehicles are firmly attached to the Engine mounting bracket. It plays very important role in performance of vehicle and its comfortable ride. As SAE India Supra car was high performance vehicle, the mounting brackets undergo high static and dynamic loading conditions due to that Huge amount of vibrations were produced. By careful designing and analysis of engine mounting bracket we can mitigate the vibration produced in the vehicle. The current paper discusses the modelling of bracket in Catia, Static and Modal Analysis of bracket was carried out in FEAST Software. Optimization of bracket is carried out in hyper mesh Software for weight reduction. A Formula Student car is required to be highly manoeuvrable and quick with high rates of acceleration and deceleration. Hence the mounting of the engine should be well constrained and the mount brackets need to be light-weight and designed to safely bear the inertial loads and maximize vibration transmission. FEA has been done to check the frequency and loading response of the brackets before finalizing the design. The design of the brackets has been experimentally validated after the actual implementation and testing of the vehicle. Finally, the comparison of results (Displacement, von-mises stresses and strain) for Mild Steel, Aluminium 6063, Carbon Fiber Composite and Glass Fiber Composite is discussed.</div></div>

In vitro study on reliability of digital scanning in duplicating removable partial dentures casts

Aim: The main purpose of this study is to determine the dimensional accuracy of digital models as compared to that of study models and the reliability of digital scanning. The study aims to measure and compare distances between selected landmarks on study models and digital models and angles of cervical convergence of the abutment teeth. Material and Methods: The study used partially edentulous study models of each of Kennedy’s class I and III classifications. All the models were scanned using scanner and digitized on the computer. The physical models and digitized models were scanned and measured using various parameters and study designs. Measurements were conducted directly on study models and computer models using Altair Hyper mesh network version 7.0. The differences between the two seta of measurement were statistically analyzed using a suitable method (t- test). Results: The differences between measurement of distance on study models and digital models were found to be within the precision of 0,08 mm and 0,21 for the angle of cervical convergence of the abutment teeth. All these measurements were statistically slightly significant and well within the range of intra operator variations. Conclusion: This study shows that dental cast can be scanned with the help of an accurate and sophisticated scanner and the scanned data can be transferred to the computer and used for the purpose of digital scanning.

Topology Optimisation of Engine Cross Members for Lightweight Structure in Light Commercial Vehicles

Topology and topography optimisations of engine cross members that were produced from sheet metal are presented. The Hyper Mesh, Opti-Struct, and Hyper-View tools in the Hyper Works software package, which is programmed by the Altair Company, were utilised in the analyses. For this purpose, two designs, software-based design optimisation (SBDOP) and expert-based design optimisation (EBDOP), were created using the trial-and-error method. The methods were compared and contrasted to the baseline in terms of the equivalent static and dynamic stiffness under both translational and rotational conditions and in terms of the linear stress distribution. In the final stage, the production design was created to conduct manufacturability analyses. Consequently, it was observed that with the use of optimisation software and tools, SBDOP can provide significant improvements in terms of time and functionality. Without violating the performance targets, such as the static and dynamic stiffness and stress distribution expected by the related OEM, the mass was reduced, and 12% improvements in weight were obtained.

Correlation of Occupant Evaluation Index on Vehicle-occupant-guardrail Impact System

Aiming at the occupant safety risk assessment of vehicle guardrail impact, a finite element model of vehicle-occupant-guardrail impact system was established and the validation of the model was verified based on the test result. Different impact speed such as 60 km/h, 80 km/h, 100 km/h, 120 km/h and different impact angle such as 25°, 30°, 35°were selected and combined to conduct 12 groups of vehicle guardrail impact simulation test by Hyper Mesh and LS-DYNA. The Acceleration Severity Index (ASI), Theoretical Head Impact Velocity (THIV), Post-impact Head Deceleration (PHD) and Head Injury Criterion (HIC) were analyzed by obtaining the longitudinal, transverse and vertical acceleration data of vehicle centroid and occupant head in the impact process. Quantitative corresponding relations between other occupant risk assessment index and Head Injury Criterion (HIC) was analyzed by SPSS, and the results showed that ASI and HIC had good correlation. Fitting degree between ASI and HIC is 0.93 with the exponential function. The study results of occupant would have guiding significance for related standards’ development and revision of related standard, experimental study and product development.

Dynamic analysis of Compressor Mounting Bracket in Automobiles

The experimental modal analysis has developed very fast since the start of digital FFT spectrum analyzer in the early 1970s. Nowadays, impact testing (or bump testing) has become well-known as quick and economical option to find the modes of vibration of a machine or structure. This paper presents the comparison of the experimental and numerical modal analysis of a compressor mounting bracket (CMB) made of Aluminum and mild steel. The dynamic behavior of CMB is investigated by performing the model analysis in Ansys-15 software. The 3-D finite element models are constructed using Altair Hyper Mesh and a numerical modal analysis is then performed to generate mode shapes and natural frequencies in three-orthogonal directions. The both finite element model agrees well with the simulation tests and eventually helps the designer to act upfront with much lesser cost and experimentation time.

Numerical Analysis On The Effect Of Various Parameters On Fracture Limit For Deep Drawn Cups

Deep drawing is the process of converting a blank into cup shaped articles like kitchen sinks, cooking pans, automobile panels, gas tanks, fountain pen caps etc. Wrinkles and fractures are the major defects in deep drawn products. Fracture is the separation or fragmentation of a solid body into two or more parts under the action of stress. In deep drawn cups tearing is usually an open crack in the vertical wall which occurs near the base due to high tensile stress that causes thinning and fracture of the metals at this location. During this process the punch force acting on the bottom of the cup is transferred to the side of the cup. The narrow ring of metal just above the bottom of the cup is subjected to plane strain condition. As a result, failure of the cup easily happens in this zone due to necking induced by the tensile stress, leading to tearing. This type of failure can also occur on the flange as the metal is pulled over the sharp die corner. In addition to this sharp corner on the punch could also cause fracture of the cup along the corner. The objective of this work is to predict the fracture limit of deep drawn cups. This would help in preventing rejections in deep drawing industry. This can be achieved by setting the blank holder force appropriately. Also it would save material and reduce the total cost. In this work numerical simulations are conducted by considering five different parameters namely punch radius, die radius, clearance, coefficient of friction and punch diameter using finite element explicit solver LSDYNA. Modeling of the set up is done using hyper mesh. In this work simulations are carried out as per L-27 orthogonal array suggested by Taguchi. A combination of finite element method and Taguchi analysis is used to determine the influence of process parameters on fracture limit in deep drawing process. During analysis the value of optimum BHF is arrived by performing a number of trial runs. Also Column effect method and plotting methods are used for finding out the most influencing parameters and their interactions respectively for analysis. The studies reveal that punch diameter is most significant parameter for deciding fracture limit followed by die corner radius and clearance. In addition to this regression analysis is carried out for developing an empirical model using Minitab 17 for predicting fracture limit.