scholarly journals Modeling and Fatigue Analysis of Robotic Arm with Lightweight Materials using FEA Technique

2021 ◽  
Vol 7 (09) ◽  
pp. 41-46
Author(s):  
K Kaleshwar Singh and Dr. K Vasantha Kumar.
Keyword(s):  
Fatigue Behavior ◽  
Dynamic Performance ◽  
Fatigue Analysis ◽  
Great Accuracy ◽  
Robotic Arm ◽  
Original Design ◽  
Lightweight Materials ◽  
Boron Fiber ◽  
Specific Strength ◽  
Good Productivity

A robotic arm is a device that can perform comparable duties to a human arm and is programmable and versatile. It is utilized to execute a variety of mechanical operations with great accuracy and efficiency for extremely repetitive jobs. Because robotic arms are employed for repetitive tasks, fatigue may occur as a result of continuous or continual loading; therefore, fatigue behavior is crucial to investigate with the lightweight materials. In this research, a robotic arm was designed and evaluated utilizing a CAD-tool (solid works) with real-time boundary conditions and five different materials (aluminum alloy 7475, carbon fiber, kevlar29, E-glass fiber, and boron fiber). There was a static analysis, a modal analysis, and a fatigue analysis. Deformations, stress, frequency values, component life, and safety considerations were all detected in these evaluations for all models. It can deduce from all of these data which materials have less deformation and which materials have lower stress levels. It can determine robot with which material to utilize for various situations, such as reduced weight or less stress generating robots with greater fatigue resistance, based on all of these findings. The created structure is compared to the metallic structure's original design. It is observed that the robot arm's stiffness has increased significantly while its mass and inertia have decreased, resulting in a very high specific stiffness, specific strength, and excellent dynamic performance, which will undoubtedly result in good productivity as per our requirements, which is the project's desired goal.

scholarly journals Multi-Objective Lightweight Optimization of Parameterized Suspension Components Based on NSGA-II Algorithm Coupling with Surrogate Model

Machines ◽  
2021 ◽  
Vol 9 (6) ◽  
pp. 107
Author(s):  
Rongchao Jiang ◽  
Zhenchao Jin ◽  
Dawei Liu ◽  
Dengfeng Wang
Keyword(s):  
Ride Comfort ◽  
Lightweight Design ◽  
Dynamic Performance ◽  
Vehicle Dynamic ◽  
Multi Objective Optimization ◽  
Original Design ◽  
Dynamic Simulations ◽  
Nsga Ii ◽  
Torsion Beam ◽  
Multi Objective

In order to reduce the negative effect of lightweighting of suspension components on vehicle dynamic performance, the control arm and torsion beam widely used in front and rear suspensions were taken as research objects for studying the lightweight design method of suspension components. Mesh morphing technology was employed to define design variables. Meanwhile, the rigid–flexible coupling vehicle model with flexible control arm and torsion beam was built for vehicle dynamic simulations. The total weight of control arm and torsion beam was taken as optimization objective, as well as ride comfort and handling stability performance indexes. In addition, the fatigue life, stiffness, and modal frequency of control arm and torsion beam were taken as the constraints. Then, Kriging model and NSGA-II were adopted to perform the multi-objective optimization of control arm and torsion beam for determining the lightweight scheme. By comparing the optimized and original design, it indicates that the weight of the optimized control arm and torsion beam are reduced 0.505 kg and 1.189 kg, respectively, while structural performance and vehicle performance satisfy the design requirement. The proposed multi-objective optimization method achieves a remarkable mass reduction, and proves to be feasible and effective for lightweight design of suspension components.

Evaluation of the Fretting Fatigue Behavior of Ti-6Al-4V Alloy

2005 ◽  
Vol 297-300 ◽  
pp. 1089-1094
Author(s):  
Jae Do Kwon ◽  
Yong Tak Bae ◽  
Sung Jong Choi ◽  
Young Suck Chai ◽  
Hitoshi Ishii
Keyword(s):  
Titanium Alloy ◽  
Fatigue Limit ◽  
Degradation Mechanism ◽  
Fatigue Behavior ◽  
Lamellar Microstructure ◽  
Fretting Fatigue ◽  
Mechanical Tests ◽  
Structural Components ◽  
Specific Strength ◽  
Fretting Damage

Fretting is a potential degradation mechanism of structural components and equipments exposed to various environments and loading conditions. It is well known that the fatigue life under fretting condition decreases approximately 50-70% compared with that under non-fretting fatigue condition. The specific gravity of titanium alloy is 4.5 which is lighter than steel, however, its specific strength, heat and corrosion resistance are superior to steel. Ti-6Al-4V alloy is a kind of a+b phase titanium alloy, and mechanical properties are changed by alloy elements, shapes and distributions of microstructures. In this study, three different kinds of specimens are prepared under different heat treatments in order to produce different microstructures. Through various kinds of mechanical tests, the following conclusions are observed: 1) The microstructures are observed as equiaxed, bimodal and lamellar microstructures respectively. 2) The elongation percentage is superior for the equiaxed microstructure, and the hardness and tensile strength are superior for the lamellar microstructure. 3) The plain fatigue limit of lamellar structure shows higher value than that of the equiaxed and bimodal structures. 4) The fretting fatigue limit considerably decreases compared with the plain fatigue limit for all materials. 5) The fretting damage of contact surface increases with an increase of cyclic loading amplitude under the constant contact pressure.

Design of Lightweight Hybrid Materials for the Cab Body-In-White of a Commercial Vehicle Based on Multi-Objective Optimization

2013 ◽  
Vol 631-632 ◽  
pp. 281-286 ◽  
Author(s):  
An Cui ◽  
Li Juan Xu ◽  
Xian Bo Zhang ◽  
Qiang Yang
Keyword(s):  
Hybrid Materials ◽  
Total Mass ◽  
Commercial Vehicle ◽  
Material Selection ◽  
Dynamic Performance ◽  
Multi Objective Optimization ◽  
Nsga Ii ◽  
Lightweight Materials ◽  
Multi Objective ◽  
Body In White

In this paper, the lightweight hybrid materials cab BIW of a commercial vehicle is investigated for material selection. In order to improve the dynamic performance and reduce total mass, the lightweight materials are employed in the BIW. Nine groups of sensitive components are selected to apply the lightweight materials. The design problem is formulated as a multi-objective nonlinear programming problem and the modified non-dominated sorting genetic algorithm (NSGA-II) is used to solve the problem. The surrogate model based on radial basis function (RBF) is adopted in the optimization. The research results show that the usage of steel-aluminum hybrid materials can reduce the total mass and increase the first torsion modal frequency of the cab BIW.

scholarly journals Validation and Improvement of a Bicycle Crank Arm Based in Numerical Simulation and Uncertainty Quantification

Sensors ◽  
2020 ◽  
Vol 20 (7) ◽  
pp. 1814
Author(s):  
R. Gutiérrez-Moizant ◽  
M. Ramírez-Berasategui ◽  
José A. Calvo ◽  
Carolina Álvarez-Caldas
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Structural Integrity ◽  
Fatigue Behavior ◽  
Dynamic Test ◽  
Element Model ◽  
Experimental Results ◽  
Original Design ◽  
Safety Requirements ◽  
Metrological Control

In this study, a finite element model of a bicycle crank arm are compared to experimental results. The structural integrity of the crank arm was analyzed in a universal dynamic test bench. The instrumentation used has allowed us to know the fatigue behavior of the component tested. For this, the prototype was instrumented with three rectangular strain gauge rosettes bonded in areas where failure was expected. With the measurements made by strain gauges and the forces registers from the load cell used, it has been possible to determine the state of the stresses for different loads and boundary conditions, which has subsequently been compared with a finite element model. The simulations show a good agreement with the experimental results, when the potential sources of uncertainties are considered in the validation process. This analysis allowed us to improve the original design, reducing its weight by 15%. The study allows us to identify the manufacturing process that requires the best metrological control to avoid premature crank failure. Finally, the numerical fatigue analysis carried out allows us to conclude that the new crank arm can satisfy the structural performance demanded by the international bicycle standard. Additionally, it can be suggested to the standard to include the verification that no permanent deformations have occurred in the crank arm during the fatigue test. It has been observed that, in some cases this bicycle component fulfils the minimum safety requirements, but presents areas with plastic strains, which if not taken into account can increase the risk of injury for the cyclist due to unexpected failure of the component.

scholarly journals Development mechanical and fatigue properties of AA7001 after combined SP with deep cryogenic treatment and UIP with deep cryogenic treatment

2021 ◽  
Vol 5 (1(113)) ◽  
pp. 62-69
Author(s):  
Aseel A. Alhamdany ◽  
Ali Yousuf Khenyab ◽  
Qusay K. Mohammed ◽  
Hussain Jasim M. Alalkawi
Keyword(s):  
Crack Nucleation ◽  
Fatigue Behavior ◽  
Low Cost ◽  
Rapid Development ◽  
Cryogenic Treatment ◽  
High Strength ◽  
Fatigue Properties ◽  
Deep Cryogenic Treatment ◽  
Tensile Test Specimen ◽  
Specific Strength

Al alloys have long been of interest to the aerospace community, due to their modest specific strength, ease of manufacture, and low cost. In recent years, with the rapid development of weaponry, 7XXX ultra-high strength aluminum alloys used increasingly in military fields. Chemical analysis of the AA 7001 is supported out at The Company State for Engineering, Rehabilitation and Inspection (SIER) in Iraq. Strengthening the surface (shot penning) is beneficial to delay crack nucleation and extend life. The test samples (tensile and fatigue) are subject to the SP process by using ball steel with the parameters (Pressure=12 bars, Speed=40 mm/min, Distance=150 mm, Shot size=2.25 mm, Coverage=100 %). The ultrasonic impact treatment (UIP) machine is used for enhancing the surface properties. For the Deep Cryogenic Treatment (DCT), the samples have been placed in the cooling chamber. A standard tensile test specimen is prepared in a round section with the dimensions chosen according to ASTM (A370-11). Tensile and fatigue of rotating bending with R=–1 have been conducting, after the effect of deep cryogenic treatment (DCT), combined shot peening (SP+DCT), and ultrasonic impact peening (UIP+DCT) of AA7001 have been examining. The maximum improvement percent in ultimate tensile strength (UTS) due to (DCT), (SP+DCT), and (UIP+DCT) were about 3 %, 8.27 %, and 6.25 %, respectively. The rise in the yield stress due to (DCT), (SP+DCT), and (UIP+DCT) were 9.5 %, 14.6 %, and 13.14 %, respectively. The ductility reduced by constituents of 8.57 %, 12.5 %, and 11.42 % sequentially. The improvement in fatigue strength in a high cycle regime is 16 % for (SP+DCT) due to combined effects, it is an 8 % increase in the endurance limit on fatigue behavior due to inducing compressive residual stress (CRS)

Assessment of Materials for Fuselage Panels Considering Fatigue Behavior

2012 ◽  
Vol 730-732 ◽  
pp. 265-270
Author(s):  
S.M.O. Tavares ◽  
P.P. Camanho ◽  
P.M.S.T. de Castro
Keyword(s):  
Composite Materials ◽  
Aluminum Alloys ◽  
Fatigue Behavior ◽  
Minimum Weight ◽  
Current Trend ◽  
Fatigue Crack Initiation ◽  
Specific Weight ◽  
Efficient Design ◽  
Damage Scenarios ◽  
Specific Strength

Minimum-weight designs are frequently too costly to manufacture, whereas less expensive and easy to fabricate and assemble designs are often much heavier. The most efficient design on the basis of both cost and weight often lies between these two extremes. The current trend in structural materials selection consists of the extensive use of composite materials in the airframe. Composite materials have high specific strength, are less prone to fatigue crack initiation and provide enhanced flexibility for structural optimization compared to the aluminum alloys. On the other hand, aluminum alloys display higher toughness and better damage tolerance in the presence of defects. A simple methodology for the weight assessment based on the specific weight for different damage scenarios for an exemplary, simplified fuselage panel, will be presented, in order to quantify the savings under different conditions. The results show that the composites have advantages over the aluminum alloys, although due to low ductility, in parts that are exposed to external damages the aluminum alloys can have better performance due to the better damage tolerant properties.

A Robust Structural Stress Method for Fatigue Analysis of Offshore/Marine Structures

2005 ◽  
Vol 127 (1) ◽  
pp. 68-74 ◽  
Author(s):  
P. Dong
Keyword(s):  
Finite Element ◽  
Fatigue Behavior ◽  
Fatigue Analysis ◽  
Finite Element Mesh ◽  
Complex Structures ◽  
Structural Stress ◽  
Marine Structures ◽  
Element Mesh ◽  
Fatigue Design ◽  
Structural Stresses

Recent rapid advances in developing mesh-insensitive structural stress methods are summarized in this paper. The new structural stress methods have been demonstrated to be effective in reliably calculating structural stresses that can be correlated with fatigue behavior from simple weld details to complex structures. As a result, a master S–N curve approach has been developed and validated by a large amount of weld S–N data in the literature. The applications of the present structural stress methods in a number of joint types in offshore/marine structures will be illustrated in this paper. The implications on future applications in drastically simplifying fatigue design and evaluation for offshore/marine structures will also be discussed, particularly for using very coarse finite element mesh designs in ship structures.

Low Cycle Fatigue Analysis of after Treatment Device Induced due to Thermal Load by Using Finite Element Analysis

2014 ◽  
Vol 592-594 ◽  
pp. 1104-1108 ◽  
Author(s):  
Swapnil Vitthal Kumbhar ◽  
Vilas Kulkarni ◽  
R.M. Tayade
Keyword(s):  
Crack Initiation ◽  
Thermal Fatigue ◽  
Thermal Loading ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Fatigue Analysis ◽  
Von Mises Stress ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Von Mises

Cyclic thermal loading causes cyclic thermal stress and thermal fatigue in the component. The goal of this paper is to characterize the thermal fatigue behavior of after-treatment (AT) device, i.e. Exhaust Gas Processor (EGP) and prediction of crack initiation cycles. The paper contains transient thermal analysis to map temperature on EGP model. By taking temperature distribution as input, Elasto-plastic structural analysis is done. Based on stress-strain data and fatigue material property, crack initiation cycles are estimated. For low cycle fatigue analysis, strain based approach, i.e. Brown-Miller Criteria with Morrow mean stress correction factor [1] is used. The von-Mises stress and crack initiation cycles are investigated and S-N curve and Ɛ-N curve are compared with standard graphs.

Stress and Fatigue Analysis of Elliptical Head with Multi-Opening in Thermal Environment

2014 ◽  
Vol 1046 ◽  
pp. 161-164
Author(s):  
Hou De Su ◽  
Jin Bo Li ◽  
Hong Bo Li
Keyword(s):  
Stress Concentration ◽  
Finite Elements ◽  
Pressure Vessel ◽  
Thermal Environment ◽  
Fatigue Behavior ◽  
Thermal Response ◽  
Fatigue Analysis ◽  
Ansys Software ◽  
Stress Evaluation ◽  
Structural Discontinuity

The mechanical and thermal response of elliptical head with multi-opening subjected to thermal loads, were carried out using ANSYS software. By dispersing the structure finite elements, the mechanical and fatigue behavior were discussed by APDL language following JB4732, and the result about stress evaluation and fatigue analysis are given, from the result, we can conclude that high first plus second stress and stress concentration may be formed at the intersection between center nozzle and elliptic, as well as between eccentric nozzle and elliptic. The structural discontinuity degree and temperature fluctuation has a big influence on stress concentration, as the most common, opening nozzle of a pressure vessel, the checking of dynamic and static of the structure, especially fatigue-checking are necessary.

scholarly journals Research On Optimization Method of Fatigue Analysis for Nuclear Pipeline

2021 ◽  
Vol 257 ◽  
pp. 02017
Author(s):  
Yuan Liang ◽  
Liu Shengyong ◽  
Yang Jie ◽  
Zhou Qiang ◽  
Zhang Guihe
Keyword(s):  
Power Plant ◽  
Nuclear Power ◽  
Optimization Method ◽  
Fatigue Analysis ◽  
Analysis Method ◽  
Pressurized Water Reactor ◽  
Original Design ◽  
Pressurized Water ◽  
Design Life ◽  
License Application

The initial design life of nuclear power plant is 40 years. In 60 year life extending license application, the fatigue of component should be evaluated under the influence of the fatigue factors of the pressurized water reactor coolant environment. Because the original design used a more conservative analysis method, the result could not meet the requirement of Cumulative usage fatigue factor of RCC-M. An optimizing analysis method is studied, and as an example of application, optimizing fatigue analysis of Safety Injection Nozzle of Main Coolant Line is performed. The evaluation results show that the optimized fatigue analysis results meet the requirements of RCC-M.

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