The research paper published by IJSER journal is about FEA IMPLEMENTION IN ANALYSIS AND OPTIMIZATION OF TOP AND BOTTOM FRAME FOR HYDRAULIC COTTON LINT BAILING PRESS 1

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FEA IMPLEMENTION IN ANALYSIS AND OPTIMIZATION OF TOP AND BOTTOM FRAME FOR HYDRAULIC COTTON LINT BAILING PRESS

A. G. Naik, N. K. Mandavgade

Abstract: This paper attempts to acquire the FEA implementation for analysis and optimization of top and bottom frame for hydraulic cotton lint bailing press. Ginning is the process of separation of fiber from cottonseed. Composite ginnery performs ginning and pressing operations to convert lint cotton into a bale. In modern day, capacity of ginning plant is such t hat the cotton bale handled by their press system gives rise to very large forces. Frame structure like all the other equipment has to be able to withstand these forces without damage. It is essential that the calculations for mechanical strength to check the suitability of top and bottom frame.

Key words: - ANSYS, Cotton bale, FEA, Failure analysis, Frame structure, Hydraulic press, optimization,

—————————— ————————

1 INTRODUCTION:

The hydraulic press is one of the oldest of the basic machine tools. In its modern form, is well adapted to presswork rang- ing from coining jewelry to forging aircraft parts. Modern hy- draulic presses are, in some cases, better suited to applications where the mechanical press has been traditionally more popu- lar. [1]The full force of a hydraulic press can be delivered at any point in the stroke. This feature is a very important cha- racteristic of most hydraulic presses. A mechanical press usually can exert several times the rated maximum force in the event of an accidental overload. This extreme overload often results in severe press and die damage. It is essential that the calculations for mechanical strength to check the suitability of top and bottom frame. For quality compare the weight if poss- ible. Try to determine the character of the frame construction. If a weldment, look at the plate thicknesses, extent of ribbing, and stress relieving [2].
So in this paper successful attempt to overcome different prob- lem of top and bottom frame, which is reported by the manu- facturer. By using the Pro/E wildfire 4.0 firstly we had devel- oped the CAD model of the top and bottom frame mechanism and than by using ANSYs software the FEM analysis of it is carried out.

————————————————

Abhijit Naik is currently pursuing MTech degree program in CAD/CAM

engineering in Mechanical Engineering Department, G. H.

Raisoni College of Engineering, Nagpur. 440016 (India) (Email: - nike.abhijit@gmail.com Contact no. 09404028910)


Due to the diversification of structural optimization problems, most structural optimization problems can be classified as size, shape and topology optimization. The main application of optimal design of steel structures is the size optimization, because this method is possible to minimize the weight of structures [4].

Fig. 1. Schematic view of Hydraulically operated up packing cotton lint baling press

Co-Author N. K. Mandavgade , Mechanical Engineering Department, G. H. Raisoni College of Engineering, Nagpur. 440016 (India) (Email: - nkmandavgade@gmail.com Contact no.09011084402 )

1.2 Hydraulically operated up packing cotton lint baling press:-

The Jadhav Zen Door-Less Bale Press is designed to be ―ener- gy efficient‖. It uses a Single 2 no's x 250 mm in diameter-ram. Features include a super high capacity lint feeder and a totally

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The research paper published by IJSER journal is about FEA IMPLEMENTION IN ANALYSIS AND OPTIMIZATION OF TOP AND BOTTOM FRAME FOR HYDRAULIC COTTON LINT BAILING PRESS 2

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enclosed right-angle gear drive tramper. A unique follow block and platen design enables square knot type wire to be applied manually and semi-automatically. Automatic strap- ping and wire tying systems are also applicable to the variable shut-height system. The Bale press consists of a frame, hy- draulic rams, and a hydraulic power system [15].

1.3 Problem Identification


Reduction of bending stresses causing bending of frame by optimizing the Top & Bottom frame.

Ra+Rd=3.206*106
SUMMATION OF ALL THE MOMENT OF FORCES ABOUT

POINT ‗A‘…………By Moment Equations
M=-(Rd*2.1) + (1.59 * 106*1.285) +(26.97*103*1.015) + (1.59 *
106*1.285) Rd=1.456* 106

Ra=1.66*106
M=-(Rd* X) + [1.59 * 106*(X-0.815)] + [26.97*103*(X-1.085)] +
[1.59 * 106*(X-1.355)……. (1)

Written above equ. In differential equ. Form

Reduction of cost and Improve safety d y

Changing the geometric structure and material of the EI

1.59

106 X

(1.59

106 )

x 0.815 2

frame -Design Optimization.

Designing an optimal thickness to minimize the max-

imum deflection of a frame for maximum economy -
Material optimization.

dx

(26.97

103)

2

x 1.085 2

2

(1.59

106 )

2

x 1.355 2

c

2 1

By again integrating above Equation we get,


EI d2 y dx2

1.59


106 x

(1.59

106 )



x 0.815

(26.97

103)


x 1.085

(1.59

106 )


x 1.355

………………………..(2)

Now by applying boundary condition

E.x. y=0 & x=0 in Equ 2
We get C1=2.03*106
From Equ. 2 we get C2= (-2.42*106)

Now by substituting C1 & C2 And boundary condition at x= 1.015

Fig. 2. Hyraulic Press with Old Top Frame & Location where the actual Failure occurs.

2 CALCULATION OF MECHANICAL STRESSES AND DEFLECTION BY DOUBLE INTEGRATION METHOD [6] [16] FOR BOTH BOTTOM AND TOP FRAME

For structural steel

IS 2062: 20006 E 250 (FE410) QA B

EIY=-675394.02 N.m ………………………….(3) E for MS material= 2*1011

Moment of inertia

I= 1/12(BD3-bd3)
I= 4.478*10-3 m3

By putting all values in equ. 3

Y=-7.5412*10-4 m
= 0.745 mm………….Deflection

For Bending stress

Young‘s modulus : 250 MPa

Poisson‘s ratio : 0.3

Density : 7850 Kg/m3

Tensile yield strength : Compressive yield strength :

M b

I Y

E .........B. ending

R

Equation

310 MPa

Tensile ultimate strength : 465 MPa [5] p.n.420]


B 56.28

10 6

N / m2 ....... i.e.Indused

Stress


TOTAL FORCE = Pressing Force (Fp) + Bell wt
= 325000 + 325 9.81
= 1.59 * 106 N
Allowable stress= 310 Mpa for ISC-20 ……..From Design data
book [05]

SUMATIONS OF ALL VERTICAL FORCES FY=Ra-1.59 * 106-26.97* 103-1.59 * 106+Rd

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f os

S yt

b

4.37

The research paper published by IJSER journal is about FEA IMPLEMENTION IN ANALYSIS AND OPTIMIZATION OF TOP AND BOTTOM FRAME FOR HYDRAULIC COTTON LINT BAILING PRESS 3

ISSN 2229-5518

By applying Max. Principal stress theory

Syt = 0.5 Sys
246 = 0.5 Sys
Sys = 492 Mpa

For Stress = Sys/FOS
= 113.88* 106


1 2 2

f m a x b b s

2 60

f m a x


145 .42 N / m 2

50 Deflection in mm

Total Bending Stress is Greater than the Bending strength on material Hence design is unsafe

3 ANALYTICAL ANALYSIS FOR TOP AND BOTTOM FRAME WITH SHOWING THE EFFECT OF SUPPORTING PLATE (RIBS) ON FRAME

40

30

20

1900

80

700

60

50

40

FOS EQUIVALENT

STRESS in

M/mm^2

East

West

Fig 30G al analyNsoisrtohf bottom fr2a0m get required FOS

Table 2

Analytical analysis for bottom frame

4. FINITE ELEMENT ANALYSIS OF TOP & BOTTOM FRAME


Finite element analysis (FEA) is a computer simulation tech- nique used in engineering analysis, it uses a numerical tech- nique called the finite element method (FEM). The finite ele- ment method (FEM) is one of the most used methods in engi- neering. These methods and programs based on it are funda- mental usage in CAD. FEA/FEM are indispensable in all en- gineering analysis where high performance is required. The main purpose of the study is to see a practical application us- ing FEA to improve design of a typical mechanical compo- nent. One of the major advantages of FEM is the simplicity of its basic concepts.[17] To perform a finite element analysis, the user must develop a calculus model of the analyzed structure. There are no algorithms and general methods for developing a unique model that approximate, with a known error, the real

NO OF

PLATE

MOMENT

OF INERTIA

b F.O.S Maximum

Deflection

structure. The development of structure of a model is based on
the intuition experience and imagination of the user. Each
model consists of lines, planes or curved surfaces and vo-
lumes, created in a 3D CAD environment. In this stage of de-
0 2.36x10^11 30.57 8.04 0.466
2 6.53X10^9 29.68 8.28 0.44
velopment, the model is continuous with an infinite number of points like the real structure.[17]
The main goal of FEM is to obtain the finite element mesh, transforming the continuous structure into a discrete model, model with a finite no of points. The boundary condition and external loads are applied to this system before solving. The result of the solution is available at the nodes of the elements. Finite element analysis can display them in graphical form to

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The research paper published by IJSER journal is about FEA IMPLEMENTION IN ANALYSIS AND OPTIMIZATION OF TOP AND BOTTOM FRAME FOR HYDRAULIC COTTON LINT BAILING PRESS 4

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analyze them, to make design decisions and recommenda- tions. Conventional analytical method for solving stress and strain become very complex and almost impossible when part geometry is very complex and almost impossible when part geometry is intricate. In such cases finite element modeling becomes very convenient means to carry out the analysis. Fi- nite element process allows discrediting the intricate geome- tries into small fundamental volumes called finite element. It is possible to write the governing equations and material properties for these elements. These elements are then assem- bled by taking proper care of constraints and loading, which result in set of equations .these equations when solved give the result that described the behavior of original complex body being analyzed.[6]
A structural shape optimization problem is set up to minimize total cost, subject to the limits on structural performance measures. For every design iteration, finite element analysis (FEA) is conducted to evaluate structural performance. The process is repeated until specified convergence criterion is satisfied. Application programs developed to integrate com- mercially available CAD/CAM/FEA/Design optimization tools enable implementation in virtual environment and facili- tate automation. The application programs can be reused for similar design problems provided that the same set of tools is used.[8]

4.1 FEA Objective:-

Primary: - Reduction of bending stresses causing bending of frame by optimizing the frame supports.
Secondary: Reduction of cost & Improve safety
The whole objective is to use FEA based simulation, and de-
termine which the best design solution is. Optimize the frame
structure by changing the design, material, structure of that
frame.

4.2 Element Selection

For most supports analysis, the element selection is made from three categories of elements:
1. Ax symmetric solid elements
2. shell/plate elements
3. 3-D brick elements.
Although nearly all problems can be solved using 3-D brick
elements, the other two types offer significant reductions in
the solution time and effort where they are applicable, There-

fore a four node quadratic shell Elements is selected [11]

4.3 Meshing

The accuracy of the FE model is highly dependent on the mesh employed In general; a finer mesh will produce more accurate results than a coarser mesh where the increased mesh density fails to produce a significant change in the results. At this point the mesh is said to be ―converged.‖[17]
Map meshing Method used for meshing with Quad Element with Element number 100.

4.4 Boundary & Loading condition

TABLE3

Boundary & Loading condition For Top frame

Parts

force(N)

due to

Punching

along upward direction

Self weight

Fix

Diplace- ment

Weight of the

Hydraulic cylinder

Top frame Old mod- el

177000

9810mm/se c2

along downward direction

At support hinged

80kg or

784.8N

TABLE4

Boundary & Loading condition For Bottom frame

Parts

force(N) due to Punching along upward direction

Self weight

Fix Diplace- ment

Weight of the Hydraulic cylinder

Top frame Old mod- el

177000

9810mm/se c2

along downward direction

At support hinged

80kg or

784.8N

5 ANALYSIS RESULT WITH OLD FRAME

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REASULT CONCLUSION FROM FEA ANALYSIS
Equivalent stress observed that Equivalent stress
>> Yield strength of material

Stress concentration at the point where failure occurs


Fig 5 Deflection occurs in OLD TOP FRAME Average value 05 mm which is undesirable

Fig 7 Equivalent Stresses 155 MPa occurs in new TOP FRA with

Rectangular cross sectional area

Fig 8 Deflection occurs in NEW OLD TOP FRAME Average value

02 mm

Fig 6 Stress Distribution flow occurs in OLD TOP FRAME

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6 FEA Optimization Processes [14]

The steps of optimization approach using topology optimiza- tion can then be stated as:
• identify the design space for the analyzed body,
• create the topology optimization model,
• formulate the optimization problem based on design re- quirements,
• perform topology optimization,
• create an optimized design based on the optimization re- sults.

Objective function: Weight Minimization
Constraints: - Equivalent stresses i.e. Yield Strength of Materi-
al (310 Mpa) and Deformation (3 mm) [5]
Parameters: - By reducing and changing No of support plate
for topology optimization Method [6][9][14]and changing the
thickness of plate (size optimization) Changing the Material
(Design optimization) [12][15][10]

7 OPTIMIZATION REASULT & DISCUSSION

Fig 10 Equivalent Stresses 432 MPa in old top frame with new design for avoid stress concentration

Table5

Comparison between Last three cases

Analysis parts

Maximum stresses

Maximum deflection

Material used

Remark

Old frame

1294

5.769

Structural steel

Failure

Modified frame

155.44

2.013

Structural steel

Less than Yield Strength

Modified

old for re-

duce stress

construction

432.96

3.642

Structural steel

IST20

Greater than Yield strength


Analytically It is found that Rectangular cross sectional top frame most suitable for Hydraulic press. Now Optimize the Rectangular cross sectional top frame.

8 FEA ANALYSIS REASULT FOR OPTIMIZATION

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design examples. Furthermore, the process starts with prelim- inary information about the component and delivers optimum components at the end.
The design calculations of Hydraulic press system are playing important role as we come to know the value of total force develops in the system. The value of tensile stresses developed in the system is greater than the permissible limit. Selection of good shape provides strength to the system as the system is only undergoing through bending according to the FEA Anal- ysis the best solution is obtained by changing the shape and design of the Top and Bottom frame structure.

10 RE REFERENCES

Fig 690E New TOP FRAME

80

TABLE 7:
COMPARISON OF CURRENT DESIGN AND NEW DE-
SIGN WEIGHT

Cur-

[1] R. Lown, "Hydraulic Presses in the 80's", Based on SME Technical Paper, MF82-918, The Society of Manufacturing Engineers, Dearborn Michigan, © 1982. The paper has been updated by Mr. Lown for subsequent public presen- tations.
[2] W. Stanley Anthony Gino J. Mangialardi, Jr "COTTON BALE PRESSES AT GINS, 1960 – 2004"

[3] Introduction to Hydraulic press, en.wikipedia.org/wiki/press.

[4] S Marco Evangelos Biancolini, Carlo Brutti, Eugenio Pez-
zuti ,"Shape Optimizations For Structural Design By
Means Of Finite Elements" Method XII ADM International

Compo- nent

FRAME

rent design weight (kg)

New

design weight (kg)

Weight

reduc- tion (kg)

Weight

reduction In Percen- tage

Conference - Grand Hotel - Rimini – Italy - Sept. 5th-7th,
2001
[5] A text book "Design data hand book ,By K madhwan,
Third edition, CBS Publication and distribution
[1] Sarfraj Naikwadi, Iqbal Momin, "Topology Optimization
of Special purpose machine frame" Users conference 3-5

WEIGHT 2146 1854 292 13

August/2006 Bangalore
[2] P.E. Uys, K. Jarmai, J. Farkas "Optimal design of Hoist

FRAME

COST (Rs)

1,60,950 1,39,050 21,900 15

structure frame" Department of Mechanical Engineering, University of Miskolc, H-3515 Miskolc Egytemvanoc, Hungary Received: 10 July 2001; received in revised form

Considering (Material cost + Fabrication cost) = Rs 75/kg

9 CONCLUSIONS

The proposed design process successfully incorporates into a structural shape optimization problem. In addition to ensuring manufacturability of the structurally optimized components, the design process delivers components with minimum cost and required performance. The trade-off between structural performance and machining cost is highlighted using these
31 March 2003; accepted 9 June 2003
[3] Edke, K. H. Chang "Shape optimization of heavy load car- rying components for structural performance and manu- facturing cost"Received: 2 May 2005 / Revised manu- script received: 8 July 2005 / Published online: 2 Febru-
ary 2006.
[4] B.Tadic, P.M.Todorovic, B.M. Jeremic "Failure analysis
and effect of redesign of a polypropylene yarn twisting
machine" Department for Production Engineering, 34000
Kragujevac, Serbia. Received in revised form 21 March
2011

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[5] H.T. S´anchez, M. Estrems, F. Faura "Analysis and com- pensation of positional and deformation errors using in- tegrated fixturing analysis in flexible machining parts" Department of Mechanical and Automation Engineering, Da-Yeh University, Changhua 51591, Taiwan (Received
16 September 2008; Revised 5 March 2009)
[6] C. Alkin, C.E. Imrak. H Kocabos "Solid Modeling and FEA
of on Overhead Crane Bridge" Acta Polytechnica Vol.45
No.3/2005
[7] Muni Prabaharan and V.AmarnathStructural "Optimiza-
tion of 5Ton Hydraulic Press and Scrap Baling Press for
Cost Reduction by Topology " International Journal of
Modeling and Optimization, Vol. 1, No. 3, August 2011
[8] Osama Bedair "Dynamic analysis of box girders with tee-
stiffening using unconstrained optimization techniques"
Received: 3 August 2009 / Revised: 20 December 2009
Struct Multidisc Optim (2010) 42:547–55
[9] LeRoy Fitzwater , Richard Khalil , Ethan Hunter "Topolo-
gy Optimization Risk Reduction" Presented at the Ameri-
can Helicopter Society 64th Annual Forum, Montreal,
Canada, April 29 – May 1, 2008.
[10] Press machine tool Manual published by
Jadhav Gear pvt ,Ltd.
[11] R. S. Khurmi and J. K. Gupta, (2005): ―A text-
book of Machine Design‖, S. Chand and
Comp. Ltd., Delhi.
[12] Ibrahim Zeid and R. Sivasubramanian ,
(2010), ―CAD/CAM Theory and Practice‖,
By, McGraw Hill. Osama Bedair "Dynamic analysis of box girders with tee-stiffening us- ing unconstrained optimization techniques" Received: 3 August 2009 / Revised: 20 De- cember 2009 Struct Multidisc Optim (2010)
42:547–55
[13] LeRoy Fitzwater , Richard Khalil , Ethan Hunter "Topology Optimization Risk Reduc- tion" Presented at the American Helicopter Society 64th Annual Forum, Montreal, Cana-
da, April 29 – May 1, 2008.
[14] Press machine tool Manual published by
Jadhav Gear pvt ,Ltd.
[15] R. S. Khurmi and J. K. Gupta, (2005): ―A text-
book of Machine Design‖, S. Chand and
Comp. Ltd., Delhi.
[16] Ibrahim Zeid and R. Sivasubramanian ,
(2010), ―CAD/CAM Theory and Practice‖,
By, McGraw Hill

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