Advanced Research Journals of Science and Technology
ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY
(ARJST)
ANALYSIS AND CASTING TOOL DESIGN OF UNDERGROUND HYDRANT CLUTCH
2349-3636
Kaiser1, Adelberto2, 1 Research Scholar, Department of Mechanical Engineering,Dresden University of Technology, Germany. 2 Professor , Department of Mechanical Engineering, Dresden University of Technology, Germany.
Abstract Underground hydrant clutch is a component used in underground piping’s for an Australian based company. The objective of this paper is to model, analyze the strength and designing casting die for the hydrant clutch. The hydrant clutch is modeled in modeling software Pro/Engineer from the drawings provided by company. The present used material for the hydrant clutch is AS1831, a grade of Ductile Cast Iron. I wanted to replace the material with another material as per client requirement, Kevlar is having less density than Cast Iron and also its strength is more. Strength validation is done for both materials Cast Iron and Kevlar, to choose the best material. Strength validation will be done using COSMOS WORKS (FEA software package) Presently Hydrant clutch is manufactured using sand Casting process. I have to prepare the total casting die to produce product through pressure die-casting process for mass production it includes, core – cavity extraction, die design and machining process (CNC program) for the core and cavity. *Corresponding Author: Kaiser, Research Scholar, Department of Mechanical Engineering, Dresden University of Technology, Germany. Published: September 08, 2014 Review Type: peer reviewed Volume: I, Issue : II Citation: Kaiser,Research Scholar (2014) ANALYSIS AND CASTING TOOL DESIGN OF UNDERGROUND HYDRANT CLUTCH
standardize the average production level of 3000 Tons per month "NELCAST" here after referred, to both the units at Gudur and ponneri together as one entity unless specifically mentioned The castings produced in NELCAST are widely used in Heavy Duty Trucks, Tractor Industry, Light commercial Vehicles, Railway equipment and Defense industry in India Nelcast also export about 50-100MT/ month to USA, Australia and are planning exports to other countries also It is a major supplier to many leading industries. INTRODUCTION TO COMPONENT
INTRODUCTION TO COMPANY NELCAST was established in 1984 at Industrial Estate, GUDUR (A.P) To Manufacture Spheroidal Graphite Iron with a capacity of 50 Tons per month. During the year 1995 to meet the increased demand from customers another Unit of NELCAST with 12,000MT capacity was put up at ponneri (Tamilnadu) under the same management. Now it is raised to 48,000 MT per annum. The unit started production during February 1996 Both the Units has more or less similar facilities and are capable of producing similar castings. The systems it existence at Gudur were implemented as ponneri unit from the beginning. The Marketing and purchase is common for both the units. Castings are produced as any one of the units as per convenience With the combined capacity of Gudur and ponneri units being 84,000 MT/Annum, NELCAST is one the largest producer of castings in the country in jobbing sector. Through the two decades of existence the Gudur facility has experienced a steady growth in its capacity, technology and customer base. We have achieved maximum production level of 3704 Tons per month and planning to
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Advanced Research Journals of Science and Technology
INTRODUCTION TO CAD Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and designdocumentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provides the user with input-tools for the purpose of streamlining design processes; drafting, documentation, and manufacturing processes. CADD output is often in the form of electronic files for print or machining operations. The development of CADD-based software is in direct correlation with the processes it seeks to economize; industry-based software (construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas graphic-based software utilizes rasterbased (pixilated) environments. MODEL
Analysis Steps : You complete a study by performing the following steps: • Create a study defining its analysis type and options. If needed, define parameters of your study. Parameters could be a model dimension, a material property, a force value, or any other entity that you want to investigate its impact on the design. Analysis Background: Linear Static Analysis Frequency Analysis Linearized Buckling Analysis Thermal Analysis Optimization Studies, Material property, Material Models, Linear Elastic Isotropic. Plotting Results. Describes how to generate a result plot and result tools. Listing Results. Overview of the results that can be listed. Graphing Results. Shows you how to graph results. Results of Structural Studies. Lists results available from structural studies. Results of Thermal Studies. Lists results available from thermal studies. Reports. Explains the study report utility. Stress Check. Lists the basics of checking stress results and different criteria used in the checking. ANALYSIS OF HYDRANT CLUTCH: CAST IRON
Meshed model
OVER VIEW OF COSMOS WORKS Cosmos works is a useful software for design analysis in mechanical engineering. That’s an introduction for you who would like to learn more about COSMOS Works. COSMOS Works is a design analysis automation application fully integrated with Solid Works. This software uses the Finite Element Method (FEM) to simulate the working conditions of your designs and predict their behavior. FEM requires the solution of large systems of equations. Powered by fast solvers, COSMOS Works makes it possible for designers to quickly check the integrity of their designs and search for the optimum solution. A product development cycle typically includes the following steps: 1 Build your model in the Solid Works CAD system. 2 Prototype the design. 3 Test the prototype in the field. 4 Evaluate the results of the field tests. 5 Modify the design based on the field test results.
REVIEW OF RESULTS
Vonmisses stress
STRESS(N/ mm2)
DISPLACEMENT
STRAIN
CAST IRON 109.028
5.953
0.0345
KEVLAR FIBER
0.104
6.198e-4
110.747
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Advanced Research Journals of Science and Technology
DIE CASTING Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes. Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing. Die casting is a method of producing alloy castings by injecting molten metal into metallic mold under pressure. Die casting process can be classified into a) Hot Chamber Process b) Cold Chamber Process
DIE ASSEMBLY
PROCEDURE OF MANUFACTURING
PRO/ENGINEER MANUFACTURING (MOLD EXTRACTION) What You Can Do with Pro/MOLDESIGN and Pro/CASTING. Pro/Moldesign is an optional module for Pro/ENGINEER that provides the tools to simulate the mold design process within Pro/ENGINEER. This module lets you create, modify, and analyze the mold components and assemblies, and quickly update them to the changes in the design model. Pro/CASTING provides tools to design die assemblies and components and prepare castings for manufacturing. Pro/MOLDESIGN and Pro/CASTING, together with Pro/ ENGINEER Foundation, provide tools to do the following: Design Part Creation and Modification
Playpath
CORE & CAVITY DESIGN WITH PRO/ENGINEER CAVITY
Vericut
CORE
NC PROGRAM G71 O0001 N0010T1M06 S5000M03 12
Advanced Research Journals of Science and Technology
G00X419.167Y5.997 G02X417.153Y-362.766I-355.721J79.509 G01X416.641Y-364.336 G02X330.189Y-505.997I-346.641J114.335 X47.271Y-457.54Z-85.69 Z0. M30 % CORE NC PROGRAM G71 O0001 N0010T1M06 S5000M03 G00X419.167Y5.997 X47.975Y-457.769Z-85.808 X47.271Y-457.54Z-85.69 Z0. M30 % CONCLUSION In my thesis, I have designed a hydrant clutch used in underground pipes. This component is currently manufactured in Nelcast Pvt. Ltd., Gudur, Andhra Pradesh. The modeling is done in Pro/Engineer. The present used material for hydrant clutch by the company is Cast Iron. I am analyzing the strength of the component using Kevlar Fiber. I am replacing material with Kevlar Fiber since its density is less than that of Cast Iron, thereby reducing the weight of the component. I have done static analysis on the component using Cast iron and Kevlar Fiber using Cosmos. By observing the results, using Kevlar for Hydrant clutch is safe. The present used manufacturing process for clutch is sand casting. I have suggested Die Casting so that it can be used for mass production. I have designed core, cavity and total die for the component. I have also generated CNC programming for the core and cavity.
References i. Jouji Kimura, 1995,“Experiments and Computation of Crankshaft Three Dimensional Vibrations and Bending Stresses in a Vee-Type Ten Cylinder Engine” SAE paper 951291, pp.1724-1732. ii. N. Hariu, A. Okada, 1997, “A Method of Predicting and Improving NVH and Stress in Operating Crankshaft Using Nonlinear Vibration Analysis”, SAE paper, 970502, pp.678-687. iii. Hans H. Muller-Slany, Prof. Dr. Ing, 1999, “Structural Damage Detection Based on Highly Accurate Updated Models”, Journal of Vibration and Acoustics, ASME Transactions, v 124, pp.250-255. iv. A. R. Heath, P. M. McNamara, 1990, “Crankshaft StressAnalysis Combination of Finite Element and ClassicalAnalysis Techniques”, Journal of Engineering for Gas Turbines and Power, ASME Transactions, v112, pp. 268275. v. H. Okamura, A. Shinno, 1995, “Simple Modeling and Analysis for Crankshaft Three-Dimensional Vibrations, Part1: Background and Application to Free Vibrations”, Journal of Vibration and Acoustics, ASME Transactions, v117, pp.70-79
AUTHOR Kaiser1, , Research Scholar, Department of Mechanical Engineering, Dresden University of Technology, Germany.
Adelberto Professor , Department of Mechanical Engineering, Dresden University of Technology, Germany.
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