Modelling and Analysis of Boron Carbide (B 4 C) Reinforcement in Aluminium Alloy (A356/LM25) Matrix Composite Using CATIA & ANSYS

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1 Modelling and Analysis of Boron Carbide (B 4 C) Reinforcement in Aluminium Alloy (A356/LM25) Matrix Composite Using CATIA & ANSYS Mr. N.Venkat Kishore 1 and Dr.K.Venkata Rao 2 1 M.Tech Scholar, Department of Mechanical Engineering 2 Professor & Head, Department of Mechanical Engineering PBR Visvodaya Institute of Technology & Science, Kavali, S.P.S.R.Nellore (D.t), A.P, India. Abstract- The objective of the present work is the modelling, Static and fatigue analysis of a model made of Aluminium Alloy (A356/LM25) reinforced with 0, 5, 7.5 and 10 weight percentage of Boron Carbide (B 4 C). The model is designed in CATIA and imported to ANSYS work bench for Static and fatigue analysis. The overall work is divided into three phases. First, modelling the object, second static and fatigue analysis and the third is analyzing the maximum von mises stress values, elastic strain and total deformation in an aluminium alloy composites. From the Ansys results, it was found that the Von mises stresses and elastic strains were increased with non linearity as the percentage increase of Boron Carbide reinforcement in the Aluminium Alloy composite. And the deformation was increased with non linearity at 0%, 5%, 7.5% of B 4 C. Again a little decrease in the deformation at 10% of B 4 C. With these results it is concluded that 7.5% B 4 C is the best composition with Aluminium matrix. Keywords- CATIA V5, ANSYS 14 Workbench, Aluminium alloy (A356/LM25), Boron Carbide (B 4 C), Von misses stress, elastic Strain and Deformation. I. INTRODUCTION 1.1 Introduction to CATIA CATIA (Computer Aided Three-Dimensional Interactive Application) started as an in-house development in 1977 by French aircraft manufacturer Avions Marcel Dassault, at that time customer of the CAD/CAM CAD software to develop Dassault's Mirage fighter jet. It was later adopted in the aerospace, automotive, shipbuilding, and other industries. CATIA is the leading product development solution for all manufacturing organizations, from OEMs (original equipment manufacturer), through their supply chains, to small independent producers. The range of CATIA capabilities allows it to be applied in a wide variety of industries, such as aerospace, automotive, industrial machinery, electrical, electronics, shipbuilding, plant design, and consumer goods, including design for such diverse products as jewellery and clothes. CATIA is the only solution capable of addressing the complete product development process, from product concept specification through product-in-service, in a fully integrated and associative manner. Based on an open, scalable architecture, it facilitates true collaborative engineering across the multidisciplinary extended enterprise, including style and form design, mechanical design and equipment and systems engineering, managing digital mock-ups, machining, analysis, and simulation. By enabling enterprises to reuse product design knowledge and accelerate development cycles, CATIA helps companies to speed-up their responses to market needs thing. Much beyond pure CAD software packages, which provide geometry modelling features for design-centric companies, CATIA delivers the keys to PLM (Product lifecycle management) for process-centric companies: 1.2 Introduction to ANSYS: ANSYS is a general purpose software, used to simulate interactions of all disciplines of physics, structural, vibration, fluid dynamics, heat transfer and electromagnetic for engineers. So ANSYS, which enables to simulate tests or working conditions, enables to test in virtual environment before manufacturing prototypes of products. Furthermore, determining and improving weak All rights Reserved 297

2 computing life and foreseeing probable problems are possible by 3D simulations in virtual environment. ANSYS software with its modular structure as seen in the graph below gives an opportunity for taking only needed features. ANSYS can work integrated with other used engineering software on desktop by adding CAD and FEA connection modules. Fig. 1: Graph of ANSYS Software with Its Modular Structure ANSYS can import CAD data and also enables to build geometry with its "preprocessing" abilities. Similarly in the same preprocessor, finite element model which is required for computation is generated. After defining loadings and carrying out analyses, results can be viewed as numerical and graphical. ANSYS can carry out advanced engineering analyses quickly, safely and practically by its variety of contact algorithms, time based loading features and nonlinear material models. II. MODELING The specimen is designed according to the procedure and specification which are given in ASTM standard. The dimensions are calculated in terms of SI Units. Length, diameter etc., parameters are taken into consideration. 2.1 CATIA- 3D Model: To design the model CATIA is used where CATIA stands for Computer Aided Threedimensional Interactive Application. It is the most powerful and widely used CAD (computer aided design) software of its kind in the world. CATIA plays a major role in the design process. In mechanical engineering CATIA enables the creation of 3D parts, from 3D sketches, sheet metal, composites, and molded, forged or tooling parts up to the definition of mechanical assemblies. Fig. 2: Drawing of Specimen as per ASTM standard Table 1: Specifications of Tensile Test Specimens Specification Dimensions (mm) Diameter 6 Distance between shoulders 50 Overall length All rights Reserved 298

3 Diameter of grip section 20 Length of the grip section 15 Thus, the dimensions for the specimen are calculated and these are used for modelling the object in CATIA-3D Model. Model was created using CATIA software which is shown in Figure 3. Fig.3: 3D Design of model using CATIA III. ANALYSIS USING ANSYS After modelling is done then analysis is done using ANSIS software. ANSYS is a general purpose software, used to simulate interactions of all disciplines of physics, structural, vibration, fluid dynamics, heat transfer and electromagnetic for engineers. 3.1 Meshing & Boundary Conditions of Model: Firstly, Automatic meshing method is used to mesh the model. Element used is 4 node Tetrahedron (Solid 285). The element size is taken as 3. Fig. 4: Meshing of Model using ANSYS In the present analysis the boundary conditions were applied on nodes at one end of the model that are activated by fixing the displacement in All DOF is Zero. And the other end is loaded by tensile force in Fx All rights Reserved 299

4 Fig. 5: Boundary Conditions applied on Model IV. RESULTS AND DISCUSSIONS 4.1 Group 0: Pure Aluminium Alloy (LM25 + 0%B 4 C) For the finite element analysis 26KN of force is used. The analysis is carried out using ANSYS software. The force is applied at the one end of model keeping the other end fixed. The maximum and minimum vonmises stress, strain and displacement are noted from the ANSYS. Fig.6: Variation of Vonmises Stresses for Group 0 (Pure Alloy) The maximum vonmises stress developed is KN/m 2 and minimum vonmises stress developed is n/m 2. Fig. 7: Variation of total deformation for Group 0 (Pure Alloy) The total Deformation is All rights Reserved 300

5 Fig. 8: Variation of total strain for Group 0 (Pure Alloy) The Maximum strain is 0.344e-5 and Minimum strain is 0.609e Group 1: Aluminium Alloy Composite (LM25 + 5% B 4 C) For the finite element analysis 28KN of force is used. The analysis is carried out using ANSYS software. The force is applied at the one end of model keeping the other end fixed. The maximum and minimum vonmises stress, strain and displacement are noted from the ANSYS. Fig. 9: Variation of Vonmises Stresses for Group 1 The maximum vonmises stress developed is KN/m 2 and minimum vonmises stress developed is N/m 2. Fig. 10: Variation of Total Deformation for Group 1 The total Deformation is All rights Reserved 301

6 Fig. 11: Variation of strain for Group 1 The Maximum strain is 0.418e-5 and Minimum strain is 0.909e Group 2: Aluminium Alloy Composite (LM % B 4 C) For the finite element analysis 30KN of force is used. The analysis is carried out using ANSYS software. The force is applied at the one end of model keeping the other end fixed. The maximum and minimum vonmises stress, strain and displacement are noted from the ANSYS. Fig. 12: Variation of Vonmises Stresses for Group 2 The maximum vonmises stress developed is KN/m 2 and minimum vonmises stress developed is N/m 2. Fig. 13: Variation of Total Deformation for Group 2 The total Deformation is All rights Reserved 302

7 Fig. 14: Variation of strain for Group 2 The Maximum strain is 0.445e-5 and Minimum strain is 0.849e Group 3: Aluminium Alloy Composite (LM % B 4 C) For the finite element analysis 33KN of force is used. The analysis is carried out using ANSYS software. The force is applied at the one end of model keeping the other end fixed. The maximum and minimum vonmises stress, strain and displacement are noted from the ANSYS. Fig. 15: Variation of Vonmises Stresses for Group 3 The maximum vonmises stress developed is KN/m 2 and minimum vonmises stress developed is N/m 2. The total Deformation is 0.626e-3mm Fig. 16: Variation of Total Deformation for Group All rights Reserved 303

8 Stress (x10 3 N/m 2 ) Deformation (mm) Fig. 17: Variation of Strain for Group 3 The Maximum strain is 0.501e-5 and Minimum strain is 0.631e Comparison of Total Deformation It can be clearly observed in Graph that for the given load the maximum total deformation of the model gets increasing with increase of B 4 C in the composite. But the increase of total deformation is not varying linearly. The slope of the curve from Group 0 to Group 1 is steeper than the curve from Group 1 to Group 2 and the curve comes down from Group 2 to Group 3. Graph 1: Deformation Vs Composition Group 0 Group 1 Group 2 Group 3 Composition 4.5 Comparison of Vonmises Stresses Graph 2: Stress Vs Composition Group 0 Group 1 Group 2 Group 3 All rights Reserved 304

9 Strain(x10-5 ) Strain(x10-5 ) 4.6 Comparison of Strain 4.7 Stress Vs Strain Curve Graph 3: Strain Vs Composition Group 0 Group 1 Group 2 Group 3 Composition Graph 4: Stress Vs Strain Group 0 Group 1 Group 2 Group 3 Stress (x10 3 N/m 2 ) IV. CONCLUSION In this conclusion, the composite model is designed using CAD software (CATIA V5R20) and analyzed using ANSYS software at various compositions, that is 0, 5, 7.5, 10% Boron carbide reinforcement in Aluminum matrix (LM25). The conclusions of the study are as follows: From the Ansys results, it is conclude that the vonmises stress is increasing from group 0 to group 3 with non linearity. From the Ansys results, it is conclude that the strain is increasing from group 0 to group 3 with non linearity. From the Ansys results, it is conclude that the deformation is increasing from group 0 to group 2. Again a little decrease in the deformation from group 2 to group 3. With these results it is concluded that 7.5% B 4 C is the best composition with Aluminium matrix. REFERENCES [1] Text book Introdcution to Ansys 10.0, R.B. Choudary. [2] [3] Toc.htm [4] [5] Jeetendra Kumar, Hussain Ahmad Parametric Analysis of Rotary Tool Electrical Discharge Machining of Metal Matrix Composite, IJERT, Vol. 3 - Issue 9 (September ) [6] Nunna Durga Prasanth, Dr.B Venkataraman Experimental Investigation and Analysis of Piston By Using Hybrid Metal Matrix IJESRT, March 2015, p [7] Dharun Lingam K, Arun Lingam K Design and Fatigue Analysis on Metal Matrix Composite Connecting Rod Using FEA IJERT, Vol.2 - Issue 12 (December - All rights Reserved 305