702024 Industrial Applications of The Finite Element Method
702024 Industrial Applications of The Finite Element Method
Coursework Assignment
Task 1 – FEA/Design Analysis of a Part Subjected to Loading
Submission Date: 3pm Thursday 21st May 2020 (50% of Module Mark)
Problem Outline
Mixed material solid supports are widely used in various applications in engineering, including oil and gas, energy, and aerospace industries. Depending on the contents, the fabrication processes and the service conditions there is often a level of safety required with the mounting, work life and use of such components. It is therefore very important that safety margins are considered and well met in designing these components.
The main objective of this specific assignment is to recognise this matter and to practice the safe design through the use of sophisticated finite element analysis commercial software.
Choice of Tasks
There are 2 solid components that you are to analyse, refine and report. The choice of component is up to you. These are, in increasing level of difficulty:
Part (a) – An Axle Mount, consisting steel and brass metals. Suitable for 3D modelling only. Redesign and Rendering required. Moderate difficulty.
Part (b) – A Vehicle Suspension Mount, consisting of steel. Suitable for complex 3D modelling only, No redesign required, but you must measure and adapt the geometry yourself. You are not limited to using Abaqus for this process. There are 2 x external connections that are not required to be modelled, but you must find methods of modelling appropriate constraints. Advanced difficulty.
Please note: Basic setup support will be given on BB for all tasks. The main aim of this coursework is to not to follow instructions, but to use your own skills to model a part. You will be expected to independently:
· Estimate and adapt loading conditions
· Apply suitable boundary conditions that represent the use of the part
· Partition and mesh the models without guidance
· Adapt the geometrical features of the part to minimise stress
Choice of Parts:
PART A – AXLE MOUNT
Sketch and measurement data will be provided for this part, suitable for 3D modelling. Steel & Brass should both be used. Implementing this part requires meshing, refinement and redesign. Partitioning will be needed to obtain an appropriate mesh. A plot of stresses (radial and hoop) through the central axis should be presented.
PART B – SUSPENSION MOUNT
This is a real, used support from a vehicle. You will need to measure the part and create a 3D model. A 3D laser scan will be provided for reference. The main skill is this part lies in defining the geometry and replicating the load conditions.
Graded Difficulty in Relation to Tasks
It is important to choose a task that you are confident of modelling correctly without extensive support. All parts, when modelling and reported correctly, are capable of being awarded marks on any point on the markscheme (see final page).
However, there are only small developments and improvements possible with Part (a), moderate developments and improvements possible with Part (a), and major developments and improvements possible with Part (b).
This graded difficulty increases the amount of independent ability and initiative you will have to implement and then report. Following the allocated markscheme, this is how more skill, research and initiative will translate into higher marks.
· You are entitled to change the task you have chosen at any time.
· For all parts, a full report that details the modelling, analysis and refinement is required to be submitted (10 pages max) and the Abaqus files for your modelled part.
· Staff support in CAD Labs for 702024 for your coursework is limited. You may use the SHU facilities at any time, but do not expect to be allocated extra resources for this coursework.
· You will be expected to work fully independently.
· You should not submit any work that is the result of collaboration.
Goals – (Applies for Parts a & b)
Goal 1: To produce an accurate geometrical model of the part in question, using appropriate materials and boundary conditions. This can be done with any software available. Reporting on meshing, seeding, element choice and any mesh refinements should be included. The following items should be delivered:
· 2D or 3D Sketches
· Axis-symmetric or 3D Parts
· Material properties (Young’s, Poisson, Yield Point – appropriately referenced)
· Boundary Conditions (fixed points, symmetries, supports, etc.)
· Seeding & Meshing
· Element types and justifications
Goal 2: To predict the structural performance of the mount in question, and make recommendations for design improvements. You will be given basic loading conditions to start the model working, but will need to estimate more appropriate static loadings that push the materials used to the point of yield stresses. This section should include several appropriate recording of values concerning:
· Static Loading (Forces, Moments, Displacements)
· Stress (Max. Principal, Von-Mises),
· Deflection & Directional Strains,
· Yield Stress of material(s) with reference to appropriate safety factors,
· Predicted points of Failure.
Goal 3: To refine/redesign the geometry and materials such that the safety of the mount is improved notably. This should involve reducing the maximum stresses around points of loading to a safe level. You may also change the minor features of the part (hole diameters, fillets, chamfering) in order to reduce stress concentrations. Different grades of material may be substituted to improve the load-bearing potential. This section should include proposals to:
· Reduce Maximum Stresses (to below yield points)
· Minimise Maximum Deflection
· Partitions & introduction of improved material choices
· Smooth surfaces & corners, re-rending the new design
· Demonstrate the improved performance of the redesigned part.
Advanced Goals – (Applies for all Parts)
If possible within the task timeframe, some extra details for completion are suggested, such as:
· Imported specific material data (i.e. ASTM standard materials)
· Multiple load cases, pre-defined fields, displacements via boundary conditions
· Plastic deformation at points of high stress (using non-linear materials data)
· Stress calculations, i.e. Von Mises (where geometry allows)
All changes and results should be reported in a concise, technical format.
Example – Basic Loading on Axis Mount (Part B)
Deliverables
1. Individual: Abaqus files x2. Include .cae and .jnl files for marking.
2. Individual: Word-processed technical report, 2000 words (maximum recommendation), .pdf format, electronic submission. Max length – 10 pages.
Deadlines
1. Submission date 3pm Thursday 21st May 2020. Report file and *.cae & *.jnl files to Blackboard.
2. Returned: within 1 month of submission.
Support Resources
A guide to the initial geometry and basic setup to each part (a-c) will be supplied on Blackboard. This will be available until the task deadline.
Notes
This assignment carries 50% of the overall module marks which are broken-down as follows:
· Task 1 – Report (individual work): 50%.
· Task 2 – ICTA: 50%.
Assessment Criteria
FOR A LARGER PRINT VERSION, PLEASE SEE BB “ASSESSMENT” FILES.
ELECTRONIC SUBMISSION ONLY.
ALL MARKS ARE SUBJECT TO CHANGE FROM THE ACES EXAM BOARD.
SUBMISSION GUIDELINES
Submit your work in the form of an electronic report (.pdf format) via the Blackboard link. If the file is too large, and ONLY if the file is too large, alternatively you could submit on either a CD/DVD via the Sheaf reception along with a completed assignment cover sheet. If you submit using Sheaf reception, please ensure you submit your work on or before the submission date specified. Finally, make sure all your drawings/images/plots are clear, readable and are accompanied by a written explanation.
Failure to submit your assignment by the hand-in date will result in a non-submission and a mark of zero will be recorded. Extensions to the assignment hand-in date can only be granted by your Student Support Manager.
You are required to make a valid attempt in this task, which must demonstrate engagement with the subject matter of the assessment set; for example, that some or all of the assessment criteria and learning outcomes are partially or fully met; and it must be capable of carrying a mark.
Normal University regulations regarding cheating, plagiarism and collusion apply, any student(s) deemed to be in breach of these regulations will be required to attend an Academic Conduct Panel and this may result in a failure of the module. Please refer to the University regulations regarding cheating, plagiarism and collusion.
Page