Finite Element Analysis Carbon Fiber Sprocket using ANSYS

IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 05, 2016 | ISSN (online): 2321-0613

Finite Element Analysis Carbon Fiber Sprocket using ANSYS Nikhil P. Ambole1 Prof. P. R. Kale2 1 Student 2Assistant Professor 1,2 Department of Mechanical Engineering 1 JSPM’s, RSSOER Narhe, Pune 2TSSM’s, BSCOER Narhe, Pune Abstract— In this study of the stress of chain drive, existing sprocket of Bajaj Pulsar 180 motorcycle is compared with the sprocket of carbon fiber material. It has been achieved by using ANSYS 13, by applying torque in to the model of sprocket. Sprocket of mild steel (MS) is considered as an object and input variables have been taken from standard conventional rear wheel sprocket model of Bajaj Pulsar 180.

Sprocket has been designed as per standard design procedure with input data of Bajaj Pulsar 180. Then CAD model is made by the commands in Catia V5 R19 of pad, pocket, fillet, and geometrical selections in part design module. Preprocessing like meshing is carried in Hypermesh 12.0. With insertion of that model into the ANSYS 13 for postprocessing with different properties of stainless steel we found different values of Von-Misses stress and total deformation. With same model of sprocket, analysis has been carried out in ANSYS 13 with different properties of carbon fiber.

Key words: Chain Drive, Sprocket of Bajaj Pulsar 180, Catia V5 R19, Hypermesh 12.0, ANSYS 13, Carbon Fiber, VonMisses Stress and Total Deformation I. INTRODUCTION Roller chain or bush roller chain is the type of chain drive most commonly used for transmission of mechanical power on many kinds of domestic, industrial and agricultural machinery, including conveyor and tube-drawing machines, printing presses, cars, motorcycles, and bicycles. It consists of a series of short cylindrical rollers held together by side links. It is driven by a toothed wheel called a sprocket.

Fig. 1: Photograph of sprocket of Bajaj Pulsar 180 A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs or even sprockets that mesh with a Chain .The name 'sprocket' applies generally to any wheel upon which radial projections engage a chain passing over it.

Sprockets are used in bicycle, motorcycle, car tracked wheel, and other machinery either to transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track, tape etc. Sprockets are of various designs, a maximum of efficiency being claimed for each by its originator. Sprockets typically do not have a Flange.

Some sprockets used with timing belt have flanges to keep the timing belt centered. Sprockets and chains are also used for power transmission from one shaft to another where slippage is not admissible, sprocket chains being used instead of belts or ropes and sprocket-wheels instead of

pulleys. They can be run at high speed and some forms of chain are so constructed as to be noiseless even at high speed.

Chain sprocket has problems like braking of bushings and/or rollers, braking of plates and pins (unusual cracks), quickly of sprockets wear quickly, Worn rollers, etc. Possible causes of these problems are significant overload, overload breakage, high impact pressure, excessive chain wear far beyond replacement level, combination of worn chain with new sprockets etc.

In this paper it is proposed to substitute the metallic sprocket of motorcycle with composite material to reduce the weight and noise. For the purpose composite material were considered namely Carbon fiber and their viability are checked with their counterpart metallic gear (Mild steel). Based on the static analysis, the best composite material is recommended for the purpose. A virtual model of sprocket was created in Catia V5 R19.

Model is imported in Hypermesh 12.0 for pre-processing and analysis is carried in ANSYS 13 After analysis a comparison is made among existing mild steel sprocket.

Based on the deflections and stresses from the analysis, we choose carbon fiber as a substitute of metal.

II. CAD MODELLING Dimensions are required for calculating of boundary conditions. Hence it’s CAD (Computer-aided design) model is necessary. The conventional sprocket model of Bajaj Pulsar 180 is used. Input for design of sprocket is taken from rear wheel sprocket of Bajaj pulsar 180. CAD model then is made by the commands in Catia V5 R19 of pad, pocket, fillet, and geometrical selections in part design module. Parametric generation of drawings will help to get the dimensions useful in forces calculations in static loading conditions on a component.

Input → Bajaj Pulsar 180 rear wheel sprocket Number of teeth=42 Chain pitch =12.7mm Sprocket diameter = 170mm Roller diameter = 8.51mm Sprocket thickness = 7.2 mm

Fig. 2: Sprocket Tooth Geometry

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Finite Element Analysis Carbon Fiber Sprocket using ANSYS (IJSRD/Vol. 4/Issue 05/2016/076)

Property Value Young’s Modulus, E 2.1x105 MPa Poisson’s Ratio ,ν 0.3 Density, ρ 7850 kg/m3 Yield Stress, σyield 250 MPa Ultimate Tensile Stress, σuts 390 MPa Table 2: Material properties of steel

Fig. 3: Tooth profile formed in Catia V5 R19

Fig. 4: 3-D model of sprocket in Catia V5 R19 III. MATERIALS FOR SPROCKET The selection of material used for the manufacturing of sprocket depends upon the strength and service conditions like wear and noise etc. also involves the cost as well as the material performance required. The sprockets maybe manufactured from metallic or non-metallic materials. The steel is widely used for the manufacturing of sprocket due to its good wearing properties, excellent machinability and ease of producing complicated shapes by machining.

Sprockets can also be supplied in various cast materials as Standard Carbon Steel (with or without hardened teeth), Stainless Steel, Special materials such as alloy steel, bronze, etc. The non-metallic materials like wood, rawhide, compressed paper and plastics like Nylon, Acrylic and Polycarbonate etc. are used for gears, especially for reducing weight and noise A. Mild Steel (MS) At present sprocket chain is made of mild steel material. So, first analysis is done using MS as material. Steel is the traditional material for sprocket chain. Steel is easy to get.

Machinery to manipulate steel is easy to get. Steel is easy and it's also cheap. This is the main reason that 99% of the sprocket chain are made from steel. Steel is stiff but dense (heavy). Steel rates well in terms of both yield strength and ultimate strength, particularly if it's carefully alloyed and processed. Steel also resists fatigue failure well which is extremely useful - even if the sprocket chain flexes under load, such flexing need not lead to a critical failure. The properties of mild steel are listed below, Structural Properties (MS):

B. Carbon Fibers Carbon fibers, more than all other fibrous reinforcements, have provided the basis for the development of PMCs as advanced structural engineering materials. Carbon fibers are commercially available with a variety of tensile moduli ranging from 207Gpa on the low side to 1035 GPa on the high side. In general, low modulus fibers have lower specific gravities, lower cost, higher tensile and compressive strengths and higher tensile strain to failure than high modulus fibers. Among the advantages of carbon fibers are their exceptionally high tensile strength to weight ratios and tensile modulus to weight ratios, very low CTEs (which provide dimensional stability in such applications as space antennas) and high fatigue strengths. The disadvantages are their low impact resistance and high electric conductivity, which may cause shorting in unprotected electrical machinery. Their high cost has so far excluded them from widespread commercial application. Carbon fibers are widely used in aerospace and some applications of sporting goods, taking advantages of the relatively high stiffness to weight and high strength to weight ratios of these fibers. The structure and properties of carbon fibers are dependent on the raw material used the process conditions of manufacture.

The manufacturing process involves the oxidation, textile precursors and pitch precursors. The most common textile precursor is PAN. Depending on processing conditions, a wide range of mechanical properties (controlled by structural variation) can be obtained, and fibers can therefore be chosen from this range so as to give the desired composite properties. Carbon fibers are commercially available in three basic forms, namely, long, continue tow, chopped (6-50mm long) and milled (30-3000μm long). The long, continues tow, which is simply a bundle of 1000160.000 parallel filaments, is used to for high performance applications.

Material properties for carbon fiber: Units Carbon Fiber E11 GPa 190 E22 GPa 7.7 G12 GPa 4.2 ν12 0.3 3 P Kg / m 1600 St1 = Sc1 MPa 870 St2= Sc2 MPa 54 S12 MPa 30 Table 3: Material properties of carbon fibers IV. FINITE ELEMENT ANALYSIS (FEA) Analysis is done by selecting appropriate solver and carrying out the operations in various stages to obtain solution. Particularly analysis is carried out in three stages by performing various operations in software.

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Finite Element Analysis Carbon Fiber Sprocket using ANSYS (IJSRD/Vol. 4/Issue 05/2016/076)

A. Pre-processing 1) Meshing In this stage IGS file is imported to the meshing software like Hypermesh 12.0. The CAD data of the Sprocket chain is imported and the surfaces were created and meshed. Since all the dimensions of the sprocket are measurable, the best element for meshing is the tetra-hedral element. Here, static analysis is used for analysis.

Fig. 5: Meshed model of sprocket in Hypermesh 12.0 No. of Nodes: 16552 No. of Elements: 62272 Element size: 2mm 2) Boundary Conditions After meshing is completed we apply boundary conditions.

These boundary conditions are the reference points for calculating the results of analysis.

Boundary Condition calculation (Pulsar 180): Gear ratio = 26.93:1 Engine torque = 14.22 Nm @ 6500 rpm ∴ Torque at rear sprocket = T e X G = 14.22 X 26.93 = 383 Nm Below figure shows loads and constraints applied in hypermesh. Sprocket has been constraint at the circumference and torque of 383 Nm is applied at the center.

with respect to the boundary conditions applied. Then on the basis of deflection it calculates strain. Once the strain is calculated we know modulus of elasticity then we can calculate the stress values. Results are viewed and accordingly modifications are suggested. Modifications are suggested according to high stress regions obtained. If the stresses are beyond the permissible limits then changes such as change in material, change in thickness of component or addition of ribs etc. are made according to suitability. The calculation of stress depends upon the failure theory suitable for the analysis.

1) Following are the results displayed for stress and deformation (MS)

Fig. 7: Von-misses stress for sprocket (MS)

Fig. 8: Displacement result sprocket chain Stress value for sprocket chain is 41.8358 N/mm2 which is well below the critical value. Hence, design is safe.

Deformation for sprocket chain is 0.004976 mm.

2) Following are the results displayed for stress and deformation(Carbon Fiber)

Fig. 6: Boundary conditions applied on sprocket in hypermesh 12.0 B. Solution and Post-Processing Meshed and boundary condition applied model is imported to the solver. Analysis process starts after applying run in the solver software. Software first calculates the deflection

Fig. 9: Von-Misses stress for sprocket (carbon fiber)

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Finite Element Analysis Carbon Fiber Sprocket using ANSYS (IJSRD/Vol. 4/Issue 05/2016/076)

Fig. 10: Displacement result for sprocket (carbon fiber) Stress value for sprocket is 371.132 N/mm2 which is well below the critical value. Hence, design is safe.

Deformation for sprocket is 0.091129 mm.

V. RESULTS The analysis of sprocket has been done for all two materials viz. steel, carbon fiber. The comparison of properties and analysis results is shown in table A and B respectively.

Steel Carbon Fiber Material E1-190 GPa 210 GPa Young’s Modulus E E2-7.7 Gpa 0.3 0.35 Poisson’s Ratio Ď… 7850 kg/m3 1600 kg/m3 Density Ď Yield Stress đ?›”đ??˛đ??˘đ??žđ??Ľđ???

290 MPa 390 MPa 2000 MPa Ultimate Tensile Stress đ?›”đ??Žđ??­đ??Ź Table 4: Comparison of material properties S. Material Max. Stress Max. Displacement No. 1 Steel 41.83 58 MPa 0.004976 mm 2 Carbon Fiber 371.132 MPa 0.091129 mm Table 5: Comparison of analysis results VI. CONCLUSION From results of finite element analysis it is observed that stresses are maximum at joint locations. It is also observed that both the materials have stress values less than their respective permissible yield stress values. So the design is safe.

From analysis results and comparison of properties of all the materials, it is found that carbon fiber is the material which is having the least density; also it is easily available and cheap as compared to other alternate materials.

Also machining cost for carbon fiber is less. Hence it is the best suited alternate material for sprocket and is expected to perform better with satisfying amount of weight reduction.

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