Design and comparative strength analysis of wheel rims of a lightweight electric vehicle using Al6063 T6 and Al5083 aluminium alloys

2020 ◽  
Vol 2 (99) ◽  
pp. 57-63
Author(s):  
T.B. Korkut ◽  
E. Armakan ◽  
O. Ozaydin ◽  
K. Ozdemir ◽  
A. Goren
Keyword(s):  
Energy Consumption ◽  
Electric Vehicle ◽  
Aluminium Alloys ◽  
Equivalent Stress ◽  
Energy Criterion ◽  
The Body ◽  
Strength Analysis ◽  
Element Analysis ◽  
Safety Belts ◽  
Von Mises

Purpose: Use of aluminium alloys in critical parts of a vehicle is common since they can combine the two important properties of a material those are being strength and lightweight. The aim in this research is to guide to design process of a wheel with taking example of an electric race vehicle implementation. Design/methodology/approach: In this study, the fatigue strengths of wheels produced for a two-person racing electric vehicle (Demobil09) are evaluated by calculating maximum distortion energy criterion (Von Mises) with Finite Element Analysis. Findings: Aluminium alloy wheels are crucial safety related components and are subjected to static and dynamic loads directly. Using FEA results, the weight and equivalent stress of the wheel are both reduced. So, the energy consumption is also decreased. Modal frequencies of the wheel models are determined. Research limitations/implications: In this paper, the materials analysed are AL6063 T6 and Al5083 aluminium alloys. Different materials can be analysed in future works. Practical implications: This paper is focusing on how to reduce the energy consumption of a two-person electric vehicle concentrating on reducing the weight of vehicle wheels. The vehicle is more technological than mass production cars since it is an electric race car which uses a hub motor, the body and chassis are produced using carbon polymer composites and all electronic units are designed and produced. Although its specialities it has homologated safety equipment like seats and safety belts. Originality/value: All boundary conditions must be analysed in details and a strength analysis must be conducted during design of the wheels for different load cases to ensure the strength of a wheel while keeping the weight as low as possible. In this complex process, this paper can give some clues to designers for strengths and weights of the designs since three different wheel forms are evaluated for reducing energy consumption of the vehicle.

An Improved Control Arm Design for a Commercial Vehicle

2021 ◽  
Author(s):  
Sinan Yıldırım ◽  
Ufuk Çoban ◽  
Mehmet Çevik
Keyword(s):  
Finite Element ◽  
Cost Effective ◽  
Element Model ◽  
Tensile Tests ◽  
The Body ◽  
Von Mises Stress ◽  
Driving Safety ◽  
Design Development ◽  
Element Analysis ◽  
Von Mises

Suspension linkages are one of the fundamental structural elements in each vehicle since they connect the wheel carriers i.e. axles to the body of the vehicle. Moreover, the characteristics of suspension linkages within a suspension system can directly affect driving safety, comfort and economics. Beyond these, all these design criteria are bounded to the package space of the vehicle. In last decades, suspension linkages have been focused on in terms of design development and cost reduction. In this study, a control arm of a diesel public bus was taken into account in order to get the most cost-effective design while improving the strength within specified boundary conditions. Due to the change of the supplier, the control arm of a rigid axle was redesigned to find an economical and more durable solution. The new design was analyzed first by the finite element analysis software Ansys and the finite element model of the control arm was validated by physical tensile tests. The outputs of the study demonstrate that the new design geometry reduces the maximum Von Mises stress 15% while being within the elastic region of the material in use and having found an economical solution in terms of supplier’s criteria.

The effects of shape memory alloys’ tension–compression asymmetryon NiTi endodontic files’ fatigue life

2018 ◽  
Vol 232 (5) ◽  
pp. 437-445 ◽  
Author(s):  
MR Karamooz-Ravari ◽  
R Dehghani
Keyword(s):  
Finite Element ◽  
Shape Memory ◽  
Numerical Models ◽  
Equivalent Stress ◽  
Element Model ◽  
Niti Shape Memory Alloy ◽  
Element Analysis ◽  
Tension And Compression ◽  
Von Mises Equivalent Stress ◽  
Von Mises

Nowadays, NiTi rotary endodontic files are of great importance due to their flexibility which enables the device to cover all the portions of curved canal of tooth. Although this class of files are flexible, intracanal separation might happen during canal preparation due to bending or torsional loadings of the file. Since fabrication and characterization of such devices is challenging, time-consuming, and expensive, it is preferable to predict this failure before fabrication using numerical models. It is demonstrated that NiTi shape memory alloy shows asymmetric material response in tension and compression which can significantly affect the lifetime of the files fabricated from. In this article, the effects of this material asymmetry on the bending response of rotary files are assessed using finite element analysis. To do so, a constitutive model which takes material asymmetry into account is used in combination with the finite element model of a RaCe file. The results show that the material asymmetry can significantly affect the maximum von Mises equivalent stress as well as the force–displacement response of the tip of this file.

Finite Element Analysis of Materials and Processing of Composite Flywheel Rotor

2014 ◽  
Vol 529 ◽  
pp. 92-96 ◽  
Author(s):  
Song Yi Guo ◽  
Chong Li ◽  
Wen Yi Li
Keyword(s):  
Finite Element ◽  
Stress Distribution ◽  
Storage System ◽  
Equivalent Stress ◽  
Energy Storage System ◽  
Element Analysis ◽  
Composite Flywheel ◽  
Flywheel Energy Storage System ◽  
Von Mises ◽  
Flywheel Rotor

Flywheel rotor is the very important component in the flywheel energy storage system (FESS). The key factors of rotor, such as rotor materials, geometry and fabrication process, have directly influence on the performance of FESS. At present, press-assembling the rotor with shrink-fit is used usually to increase strength of composite flywheel rotors filament wound in the radial direction. This paper is concerned that the Von Mises equivalent stress distribution of the metal hub and the radial stress distribution of the composite rim at the speed of 20000rpm by the 3D finite element method. The materials and corresponding minimum value of interference fit of the flywheel rotor are determined based on the analysis results.

scholarly journals Effect of cartilage thickness mismatch in osteochondral grafting from knee to talus on articular contact pressures: A finite element analysis

2021 ◽  
Vol 32 (2) ◽  
pp. 355-362
Author(s):  
Ömer Faruk Kılıçaslan ◽  
Ali Levent ◽  
Hüseyin Kürşat Çelik ◽  
Mehmet Ali Tokgöz ◽  
Özkan Köse ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Contact Pressure ◽  
Equivalent Stress ◽  
Cartilage Thickness ◽  
Frictional Stress ◽  
Element Analysis ◽  
Grafting From ◽  
Von Mises ◽  
Osteochondral Grafting

Objectives: The aim of this study was to investigate the effect of cartilage thickness mismatch on tibiotalar articular contact pressure in osteochondral grafting from femoral condyles to medial talar dome using a finite element analysis (FEA). Materials and methods: Flush-implanted osteochondral grafting was performed on the talar centromedial aspect of the dome using osteochondral plugs with two different cartilage thicknesses. One of the plugs had an equal cartilage thickness with the recipient talar cartilage and the second plug had a thicker cartilage representing a plug harvested from the knee. The ankle joint was loaded during a single-leg stance phase of gait. Tibiotalar contact pressure, frictional stress, equivalent stress (von Mises values), and deformation were analyzed. Results: In both osteochondral grafting simulations, tibiotalar contact pressure, frictional stress, equivalent stress (von Mises values) on both tibial and talar cartilage surfaces were restored to near-normal values. Conclusion: Cartilage thickness mismatch does not significantly change the tibiotalar contact biomechanics, when the graft is inserted flush with the talar cartilage surface.

New realistic hypothesis on corner stiffness of right-angle frames for increased analysis accuracy

2015 ◽  
Vol 231 (9) ◽  
pp. 1738-1748
Author(s):  
Young-Doo Kwon ◽  
Jin-Sik Han
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Equivalent Stress ◽  
Frame Structure ◽  
Element Analysis ◽  
Optimal Dimension ◽  
Various Boundary Conditions ◽  
Wide Range ◽  
Von Mises ◽  
Comparison Of The Results

Structural elements like bars, trusses, beams, frames, plates, and shells have long been used in structures and machines because of their large stiffness-to-weight ratios. The Euler–Bernoulli theory for beam elements is currently used in a wide range of engineering fields. Frames may essentially be considered to be a type of general beam with axial loads. In the analysis of a right-angle frame, the stiffness of a corner has been assumed to be infinite, which is allowable only when the frame is sufficiently slender. However, a comparison of the results of a finite element analysis showed that the assumption of rigid corner stiffness is unacceptable for most cases because of the considerable errors that result. To resolve this problem, we assumed that the stiffness of a corner in a right-angle frame was finite, which is mostly the case, and solved the problem of a right-angle frame with round corners under internal pressure. Using the derived formula based on the assumption of finite corner stiffness and the formula for the round corner stiffness, we analyzed the entire right-angle frame structure and compared the results to finite element analysis results. As a final attempt, the quasi-optimal dimension of the corner was found to exhibit the lowest von Mises equivalent stress. This proposed approach could be applied to many problems involving frames with various boundary conditions to improve the accuracy.

Finite Element Analysis of the Tractor Front Axle Housing Based on ANSYS

2011 ◽  
Vol 105-107 ◽  
pp. 168-171
Author(s):  
Dong Fang Hu ◽  
Wen Hui Liu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Equivalent Stress ◽  
Vertical Displacement ◽  
Front Axle ◽  
Weak Links ◽  
Strength Analysis ◽  
Element Analysis ◽  
Design And Optimization ◽  
Structural Improvement

This paper shows the static strength analysis of the tractor front axle housing by using of the finite element analysis software ANSYS, visually shows equivalent stress and strain distribution and vertical displacement distribution of the front axle housing. At the same time it also shows the analysis results of the model processing, the results of accuracy and reliability, and the weak links of the structure. By analyzing the weakest link and the difference in strength between each node for the overall structure in the condition, it can provide a direction and theoretical basis for the design and optimization of geometric entities. And the results of the analysis may be as the basis for structural improvement. In this way, it can be verified that using computer virtual software for product development is positive.

scholarly journals Elastic stress concentration at radial crossholes in pressurized thick cylinders

2007 ◽  
Vol 42 (6) ◽  
pp. 461-468 ◽  
Author(s):  
T Comlekci ◽  
D Mackenzie ◽  
R Hamilton ◽  
J Wood
Keyword(s):  
Stress Concentration ◽  
Maximum Stress ◽  
Equivalent Stress ◽  
Three Dimensional ◽  
Maximum Principal Stress ◽  
Radius Ratio ◽  
Graphical Form ◽  
Element Analysis ◽  
Parametric Finite Element Analysis ◽  
Von Mises

Results of a parametric finite element analysis investigation of stress concentration at radial crossholes in pressurized cylinders are presented in numerical and graphical form. The analysis shows that the location of maximum stress does not generally occur at the junction between the bores, as is commonly supposed, but at some small distance up the crosshole from the junction. Maximum stress concentration factors (SCFs) are defined on the basis of the maximum principal stress, von Mises equivalent stress, and stress intensity. Three-dimensional plots of the SCF against the cylinder radius ratio b/a and the crosshole-to-main-bore-radius ratio c/a are presented. The SCFs were found to vary across the range of geometries considered with local minima identified within the parameter range in most cases. The results therefore allow designers to select optimum b/a and c/a ratios to minimize stress concentration in real problems.

Rational Stress Limits and Load Factors for Finite Element Analyses in Pipeline Applications: Part I—Linear Elastic Stress Limit Development

2010 ◽  
Author(s):  
Bisen Lin ◽  
Richard C. Biel
Keyword(s):  
Finite Element ◽  
Equivalent Stress ◽  
Element Model ◽  
Element Analysis ◽  
Linear Elastic ◽  
Stress Limit ◽  
Load Factors ◽  
End Conditions ◽  
Von Mises Equivalent Stress ◽  
Von Mises

In this paper, a rational stress limit based on the von Mises equivalent stress is established for pipelines subjected to internal pressure. This stress limit is based on the ASME pipeline Code’s design margin for the service and location of the installation [1, 2]. These Codes are recognized by 49 CRF192 [5]. Both capped-end and open end conditions are considered. The single value of stress limits can be derived by classical hand calculations for use in assessing the results of a finite element analysis (FEA). Two application examples are presented showing studies done with the ABAQUS [3], a commercial (FEA) software. A stress limit was first found using classical hand calculations and verified by a simple finite element model. The linearized stresses at some critical locations were then compared to the established stress limit, and multiples, for the assessments of membrane, membrane plus bending, etc. stresses. This paper is not intended to revise or replace any provision of ASME B31.8 [2]. Instead, it provides a rational stress limit that may be used in the assessment of detailed FEA analyses of pipelines and the associated components.

scholarly journals Patient-Specific Static Structural Analysis of Femur Bone of different lengths

2018 ◽  
Vol 12 (1) ◽  
pp. 108-114 ◽  
Author(s):  
K.N. Chethan ◽  
Shyamasunder N. Bhat ◽  
Mohammad Zuber ◽  
Satish B. Shenoy
Keyword(s):  
Body Weight ◽  
Structural Analysis ◽  
Anatomical Variation ◽  
The Body ◽  
Von Mises Stress ◽  
Patient Specific ◽  
Element Analysis ◽  
Load Bearing ◽  
Femur Bone ◽  
Von Mises

Background:The femur bone is an essential part of human activity, providing stability and support in carrying out our day to day activities. The inter-human anatomical variation and load bearing ability of humans of different heights will provide the necessary understanding of their functional ability.Objective:In this study, femur bone of two humans of different lengths (tall femur and short femur) were subjected to static structural loading conditions to evaluate their load-bearing abilities using Finite Element Analysis.Methods:The 3D models of femur bones were developed using MIMICS from the CT scans which were then subjected to static structural analysis by varying the load from 1000N to 8000N. The von Mises stress and deformation were captured to compare the performance of each of the femur bones.Results:The tall femur resulted in reduced Von-Mises stress and total deformation when compared to the short femur. However, the maximum principle stresses showed an increase with an increase in the bone length. In both the femurs, the maximum stresses were observed in the medullary region.Conclusion:When the applied load exceeds 10 times the body weight of the person, the tall femur model exceeded 134 MPa stress value. The short femur model failed at 9 times the body weight, indicating that the tall femur had higher load-bearing abilities.

scholarly journals Biomechanical behavior of overdentures supported by different implant position and angulation using Micro ERA® system

2019 ◽  
Vol 18 ◽  
pp. e191667
Author(s):  
Felipe Franco Ferreira ◽  
Guilherme Almeida Borges ◽  
Letícia Del Rio Silva ◽  
Daniele Valente Velôso ◽  
Thaís Barbin ◽  
...  
Keyword(s):  
Finite Element ◽  
Tensile Stress ◽  
Equivalent Stress ◽  
Lateral Incisor ◽  
Von Mises Stress ◽  
Element Analysis ◽  
Bone Implant ◽  
Implant Position ◽  
Biomechanical Behavior ◽  
Von Mises

Aim: The aim of this study was to investigate the biomechanical behavior of implant-retained mandibular overdentures using Micro ERA® system with different implant position and angulation by finite element analysis (FEA). Methods: Four 3D finite element models of simplified mandibular overdentures were constructed, using one Bränemark implant with a Micro ERA® attachment. The implant was positioned on the canine or lateral incisor area with an angulation of either 0º (C-0º; LI-0º) or 17º (C-17º, LI-17º) to the vertical axis. A 100 N axial load was applied in one side simultaneously, from first premolar to second molar. In all models it was analyzed the overdenture displacement, compressive/tensile stress in the bone-implant interface, and also the von Mises equivalent stress for the nylon component of the housing. The stresses were obtained (numerically and color-coded) for further comparison among all the groups. Results: The displacement on the overdenture was higher at the posterior surface for all groups, especially in the C-17º group. When comparing the compressive/tensile stress in the bone-implant interface, the lateral-incisor groups (LI-0º and LI-17º) had the highest compressive and lowest tensile stress compared to the canine groups (C-0º and C-17º). The von Mises stress on the nylon component generated higher stress value for the LI-0º among all groups. Conclusions: The inclination and positioning of the implant in mandibular overdenture interferes directly in the stress distribution. The results showed that angulated implants had the highest displacement. While the implants placed in the lateral incisor position presented lower compressive and higher tensile stress respectively. For the attachment the canine groups had the lowest stress.

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