Stress Analysis on HDPE fuel tank for Maruti Alto Car

Transcription

1 2016 IJSRST Volume 2 Iue 6 Print ISSN: Online ISSN: X Themed Section: Engineering and Technology Stre Analyi on HDPE fuel tank for Maruti Alto Car Sheikh Mohd Shadab, R. N. Dehankar, A. P. Ganorkar Mechanical Engineering Department, Anjuman College of Engineering and Technology Nagpur, Maharahtra, India ABSTRACT The aim of thi project i to deign a HDPE fuel tank baed on exiting deign, which i already ued in Maruti alto car a ame pecification of original teel tank and obtain a comparative tudy on weight and different factor uing material a High Denity Poly-Ethylene.a to obtain a comparative tudy. The project conit of optimization of the model to get bet deign output obtained from analyi reult and then modified the HDPE model. Thi modification are baed on changing the hape of the exiting model by taking advantage of the metallurgical propertie of HDPE and Analyzing it on the ame parameter of the original fuel tank. Keyword: HDPE, Fuel Tank, Analyi. I. INTRODUCTION Platic fuel tank intead of teel tank have been ued in recent year due to their everal advantageou propertie uch a their light weight, low material and production cot, high afety level, greater capacity due to greater choice of hape, non-corroivene property and good deign flexibility In 1972, VW Paat car with platic fuel tank were manufactured for the firt time a a ma production. Since then the major automobile manufacturer around the world have tarted to how interet in and to work on the ue of the platic fuel tank. Platic fuel tank date back to the early The ucce of Volkwagen ue of high molecular weight polyethylene tank in the early 1970 ha coniderably influenced the growth of HDPE fuel tank in North America (WOOD, 1991).During the late1980 and early 1990, American companie began experimenting with uing platic fuel tank. Landberg, Germany Delphi tudie forecat that by the year 2000, 40% of all North American-produced paenger car and light truck will have platic fuel tank and 60% will have teel tank. By the year 2005, they forecat that 60% of fuel tank will be made of platic and 40% will be made of teel. II. METHODS AND MATERIAL A. Working Methodology 1) In thi project the exiting fuel tank of Maruti alto Car i taken and deign it in olid work oftware ued for deigning of CAD model. The deign of fuel tank i ame a original deign without changing it dimenion and hape. 2) The next tep to be the tage free vibration analyi to check the tiffne of deign model whether it can utain the Finite Element Analyi. 3) To third tep i perform Finite Element analyi on the model with boundary condition and other tet a given in the norm of Automotive Reearch Aociation of India (ARAI). 4) To perform the finite element analyi on the model with ame condition but replacing material with HDPE (High Denity Poly-Ethylene) 5) To optimize the model by having analyi reult on different thickne. 6) Selecting appropriate thickne for model a it deign hould be afe with having ome factor of afety. 7) Now, the exiting model i modified in it hape in accordance to obtain better reult than exiting HDPE model reult. 8) To compare the exiting model and new Model on different parameter hown in below chapter. IJSRST Received : 01Dec 2016 Accepted : 12 Dec 2016 November-December-2016 [(2)6 : ] 343

2 B. Material The material I have elected for thi tudy are: 1) High pot Denity Poly-Ethylene 2) Steel Table 1. Element count of the mehed model Sr No Element Type Count 1 TRIA QUAD RBAR 546 Material Denity(ρ)Kg/ m3 Young Modulu (E) GPa HDPE 970 kg/m3 1.2 Gpa 0.3 STEEL 7890 kg/m3 210 Gpa 0.3 C. Modeling And Analyi of HDPE Fuel Poion Ratio (μ) The model i deign in olid work a per the original pecification and geometry ued in maruti alto car Figure 3. Mehed model D. Tet and Boundary Condition Hydraulic Tet The tank mut be ubjected to a hydraulic internal preure tet, which mut be carried out on an iolated unit complete with all it acceorie. The tank mut be completely filled with a non-flammable liquid Figure 1. Iometric view of the 3d Model. Figure 4. Boundary condition for hydraulic tet with internal preure 0.3 Bar Overturn Tet Mehing of the model Figure 2. Detailing of the model Mehing i a kilfulne in FEA in which model i mehed in mall number of element. There are different type of element quare, rectangular bar triangular element etc. 1) The tank and all it acceorie mut be mounted on to a tet fixture in a manner correponding to the mode of intallation on the vehicle for which the tank i intended; thi alo applie to a ytem for the compenation of the interior exce preure. 2) The tet fixture hall rotate about an axi lying parallel to the longitudinal vehicle axi. 344

3 3) The tet hall be carried out with the tank filled to 90% of it capacity and alo 30% of it capacity with a non-flammable liquid having a denity and a vicoity cloe to thoe of the fuel normally ued (water may be accepted) Back Side Figure 7. Maximum diplacement = 14.1 mm Figure 5. Liquid preure on bottom face Vonmmie Stre Plot Figure 6. Liquid preure on left ide face Figure 7. Liquid preure on right ide face III. ANALYSIS RESULTS Figure 9. Maximum Vonmmie tre = 9.40 MPa B. F. E. A Reult (Overturn Tet - HDPE) For 5 mm Thick A. F. E. A Reult (Hydraulic Tet - HDPE) For 5 mm Thick Diplacement Plot: Figure 10. Maximum diplacement = 4.98 mm Front Side 345

4 IV. CONCLUSION In thi project the objective i to obtain comparative tudy of fuel tank for Maruti alto car in which the original Deign model of teel fuel tank ha taken. With related dimenion a CAD model i deign and perform an FEA analyi on it. Figure 11. Maximum Vonmmie tre = 5.05 MPa V. RESULT A we have carried the hydraulic tet and over turn tet on variou thicknee for the HPDE, the reult of HPDE with 5 mm thickne are afe and alo the weight lowered compared to conventional metallic deign. Thu we have finalized the deign which would be optimized further. Metallic Table 2. Tet Reult Hydraulic tet HDPE Diplacemen t (mm) Stre (mpa ) Thickne (mm) Diplacemen t mm Stre (mpa ) Table 3. Table howing weight of tet conducted Metallic Weight (kg) HDPE Weight (kg) mm mm mm Thi table how the reduction of weight of metallic tank and HDPE tank The material ued i HDPE (High Denity Polyethylene) for tank a an alternative with depth of 3mm, 4mm and 5 mm. The 3mm and 4mm i weakne where the depth with 5 mm i afe and under deign condition a the yield tre for HDPE material i 15 Mpa 1) For 3mm depth tre i 24.5 Mpa greater then 15 Mpa failing the deign Criteria. 2) For 4mm depth tre i 14.4 Mpa near about to 15 Mpa,which cannot be conidered a it ha no Factor of afety. 3) For 5 mm depth tre i 9.40 Mpa le then 15 Mpa can be conider an ha Factor of afety. So electing 5 mm depth for HDPE fuel tank and other parameter are alo i afe hown in above table. The exiting model i alo being modified to optimize the model, thi optimization ha done on the hape of the exiting model and hown by Finite Element Analyi, now we can dre warmly that our modified model i better than exiting model a i reduce more weight than Exiting HDPE Model The depth of 5mm HDPE fuel tank ha tre of 9.40 Mpa and modified HDPE fuel tank of thickne 5 mm ha tre 4.16 Mpa but cutom-made HDPE fuel tank of depth 4 mm ha tre of 8.46 Mpa. Since the modified deign of 5mm depth produce much lower and afe reult, thu we have changed the depth back to 4 mm which produce afe reult and thu the final deigned i elected. The weight Reduce by % a comparion of exiting teel Fuel tank and optimized HDPE fuel a hown in above table. V. REFERENCES [1] H. Burak Utaoğlu1*, Sena Ayhün2, Gokay Simitçioğlu2, Sedat Süler2, Erdem Akay2, Vedat Z. Doğan2, Zahit Mecitoğlu2, Halit S. Türkmen2, Serter Atamer1 1Mercede-Benz Türk, Itanbul 34519, Turkey 2Itanbul Technical Univerity, 346

5 Aeronautic and Atronautic Faculty, Itanbul 34467, Turkey [2] H. V. Chavan Dattakala Group of Intitution Faculty of Engineering, Swamichincholi, Pune, India..Prof. S. R. Gawade Dattakala Group of Intitution Faculty of Engineering, Swamichincholi, Pune, India. [3] Hiroaki Himeki, Hirohi Kumagai and Katumi Morohohi, Fatigue Behavior Analyi and Durability Evaluation of Platic Fuel Tank, Nian Motor Co., Ltd, 2006 SAE World Congre Detroit, Michigan April 3-6, 2006, pp [4] Pierre Delbarre and Antonio Rod,Barrier Technologie Applied to Platic Fuel Tank Comparion of Their Performance, VIIth International Mobility Technology Conference & Exhibit Sao Paulo, Brazil October 4 to October 6, 1999, pp Rakheja. S, Sankar. S and Ranganathan. R., Influence of Tank Deign Factor on the Rollover Threhold of artially Filled Tank [5] Vehicle. SAE World Congre Detroit Michigan May 8-7, 2009, pp