BUCKLING AND CRUSHING ANALYSIS OF CYLINDRICAL ALUMINIUM CANS & OPTIMIZING THE PARAMETERS EFFECTING CRUSH STRENGTH USING FEM

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1 BUCKLING AND CRUSHING ANALYSIS OF CYLINDRICAL ALUMINIUM CANS & OPTIMIZING THE PARAMETERS EFFECTING CRUSH STRENGTH USING FEM Sawant D. A. 1, Dr. Venkatesh M. A. 2 1Student, Dept. Of Mechanical Engineering, S.N.D C.O.E & R.C YEOLA, MAHARASHTRA, INDIA 2Principal, S.N.D C.O.E & R.C YEOLA, MAHARASHTRA, INDIA *** Abstract - Beverage industries face a lot of problem of 2. LITERATURE REVIEWS wastage of beverage drinks due to the collapse of aluminium Belblidia et al. presented a simulation study of an aerosol cans which lead to decrease in the profit and disturbance in can considering internal pressure and compressive loading economical balance of the company. In order to increase the to obtain various parameters effecting can s crushing effectiveness of the cans effect of impact loads on the cans is strength and provided a provided a guidance to improve considered in this study. Usually cans are designed as pressure aerosol can design. [1] Folle et al. studied various parameters vessels but it leads to failure of cans during impact loads. In affecting the manufacturing process of beverage cans. this work the impact loads are taken into consideration and Parameters such as angle of ironing die, friction coefficient crashing analysis of aluminium cans is performed with the aim and clearance between punch and ironing die influence the of finding out the ability of cans to withstand impact loads ironing force and consequently the manufacturing process [2] using FEM. Various factors effecting crushing strength is Foster experimentally obtained various radial deformation identified. It is found that thickness of sheet and mass of patterns in thin walled cylinders and further obtained a crusher play a very vital role in crash test mathematical relation to obtain radial deformations. [3] Further Han et al. performed crushing analysis on triangulated aluminium beverage can and optimized the Key Words: Aluminium can, Buckling Load, Crushing, Compression, Loading. 1.INTRODUCTION An Aluminum can is a container for packaging made primarily of aluminum which is commonly used for foods and beverages but also for products such as oil, chemicals, and other liquids. It is used for packaging of food so it is subjected to various external loads while transportation. The major problem associated with aluminium cans is the inability of cans to withstand the impact loads which leads to wastage of lot of beverage drinks and other stuffs. Aluminium cans are designed to withstand the internal pressure exerted by the fluids but the effect of impact which may occur during transportation is considered as a negligible factor. In this case the effect of impact loads on the cans will be taken into account and various factors involved in effecting crash of cans will be considered. This study is performed in order to increase the effectiveness of aluminium cans. In this work three piece aluminium can is subjected to both buckling and crashing failure under the applied loads to find the crushing strength of aluminium can. design to obtain best performance using response surface approximation [4] again Han et al. performed crushing analysis but shape of the can was considered to be cylindrical. [5] In the same way Han et al. again perform crushing analysis and optimization but considered aluminum beverage bottle design in place of can. [6] Ceretti et al. studied another manufacturing process of aluminium cans: Hydroforming both experimentally and numerically. Numerical simulations were perfomed to find out various parameters affecting manufacturing process. [7] Furthermore, Abrinia et al. Abrinia studied extrusion as a manufacturing process for aluminium cans. [8] Moreover Courbon studied the mechanical properties of aluminium alloy. used in manufacturing of beverage cans. [9] Xu et al. studied experimentally the crashworthiness performance of thin walled aluminium structures. It was found that functionally graded tubes perform better than uniform thickness counterparts. [10] Mhuruyengwe et al. performed finite element analysis on metal food cans. [11] 3. METHODOLOGY Methodology usually adopted for the Production of the aluminium cans is that the dimensions of the can are calculated with help of internal pressure of the liquid which it has to withstand and proper factor of safety. After getting the safe dimensions aluminium cans are manufactured using either forming or deep drawing. [2],[7],[8] The crushing analysis in this study is performed on aluminium can made up of aluminium alloy 1100 with three different thickness 0.11, 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Journal Page 3081

All the numerical simulations are performed with the help of ABAQUS 14.0. Table -1: Dimensions of Aluminium Cans Sample Diameter (D0) Thickness Depth S_11 80 mm 0.11 mm 80 mm S_22 80 mm 0.

2 0.22 and 0.33 mm sheets respectively. Firstly the maximum load under which the aluminium cans buckle is calculated and that buckle load is further used for the explicit dynamic crushing analysis of cans. All the numerical simulations are performed with the help of ABAQUS Table -1: Dimensions of Aluminium Cans Sample Diameter (D0) Thickness Depth S_11 80 mm 0.11 mm 80 mm S_22 80 mm 0.22 mm 80 mm S_33 80 mm 0.33 mm 80 mm A thin cylindrical shell is designed with external diameter 80 mm, 80 mm depth and different thicknesses 0.11, 0.22 and 0.33 mm respectively to perform different crush and buckling test for each specimen. loading to attain crushing strength of each can. In this phase the maximum load obtained in the first phase is used as an input along with time increment of 1 Second. 4. EXPERIMENTAL SETUP & ANALYSIS After the samples were fabricated, they were subjected to static load in Compression Testing Machine. This Compression Testing Machine is a hydraulic, electrically operated unit, designed for conducting compression tests on concrete specimens up to 20 cm. Diameter (or width and depth) and 30 cm, in height and also rocks and various other materials. Cold Crushing Strength (CCS) test is also possible in this Compression Testing Machine. The Compression Testing Machine consists of a steel cross head and cast iron base with two pillars connecting the base and cross head by means of nuts. The hydraulic jack of this Electric Compression Tester is fixed to the base. The upper platen has got a self-aligning action and is attached to a screw which passes through the cross head and can be raised or lowered for initial clearance adjustment. The lower platen rests on the jack ram and is positioned with the help of a centre pin. Loading is accomplished by the upward movement with the help of a centre pin. Loading of Compression Testing Machine is accomplished by the upward movement of the motorized pumping unit is of plunger type and is connected to the jack by means of a steel connecting tube. A maximum red pointer is provided to facilitate taking of the readings after failure of specimens. The pressure gauges of 20 cm diameter with isolating valves are fixed on the pumping unit at an angle for easy readability. Fig -1: Aluminium Can Table -1: Properties Of AL1100 Properties Values Density 2710 kg/m 3 Poisson s ratio 0.33 Tensile Strength Yield Strength Shear Strength 110 MPa 105 MPa 69 MPa Fig -2: Crush Strength Of Can Sample Percentage Elongation 12% The material used in this analysis is Al 1100 alloy with properties as given in the above table. The aluminium can analysis is carried out in two phases: In the first phase buckling analysis of each sample of can is carried out to find the maximum load under which a structure fails and in second phase can samples are subjected to explicit dynamic 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Journal Page 3082

Fig -3: Compression Testing machine Aluminium cans with 80 mm diameter and depth 80 mm are prepared with different thickness 0.11 mm, 0.22 mm and 0.33 mm respectively.

The samples are crushed till the maximum displacement of the sample is reached and the maximum or peak load is noted. 5.

3 Fig -3: Compression Testing machine Aluminium cans with 80 mm diameter and depth 80 mm are prepared with different thickness 0.11 mm, 0.22 mm and 0.33 mm respectively. After preparing the samples are subjected to compression tests with the help of compression testing machine. The samples are crushed till the maximum displacement of the sample is reached and the maximum or peak load is noted. 5. RESULT & DISCUSSSION The results and discussion in this study is divided in two different sections- Buckling analysis of can and Crushing analysis of can. 5.1 Buckling Analysis It is a simple static analysis performed in ABAQUS 14.0 to find out the maximum load which a structure can withstand without failure. In this analysis meshing is performed with the help of S4R elements. Initially 1 kn load is applied at the centre by creating it as a control point with MPC constraint so that the load is distributed equally to all nodes with which it is connected. Fig -5: Maximum Load On Each Sample The maximum buckling load carried by the aluminium can of 0.33 mm thickness sheet is 850 N. The maximum load carried by 0.22 mm thickness aluminium can is 586 N while load carried by 0.11 mm thickness aluminium can is 427 N. The above graph represents that as the thickness of the sheet increases with which can is manufactured the maximum load carrying capacity of a structure without failure also increases mm sample aluminium can withstands the maximum load out of three samples tested. 5.2 Crushing Analysis Each sample of aluminium can has specific maximum load which is used as input for further analysis. Maximum load is applied as an input parameter for each case separately to perform its crush test. Crushing is a time dependant phenomena thus the loading conditions become more complex as compared to static analysis. In crashing a crasher or moving wall is created which is used to crush the can. In this case a square shell with 100 mm X 100 mm and 1 kg mass is crusher or moving wall. The square crusher is chosen with a rigid plastic model for analysis. Fig -4: Buckled Aluminium can 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Journal Page 3083

4 5.4 Effect of Mass Of Crusher Crushing analysis is also performed on 0.33 mm aluminium can with varying masses of the crusher as 1 kg, 2 kg and 3 kg respectively in order to observe the effect of mass of crusher on performance and crushing strength of cans. Fig -6: Crushing of Sample S_33 having [80, 80] Co-ordinate System. The load is applied in time step incremental form to perform explicit dynamic analysis. The crusher wall is restricted to move in any direction other than downward with a velocity of 1 m/s. 5.3 Effect of Thickness Of Sheet Crushing analysis is performed in three different samples of aluminium cans with three different thickness 0.11, 0.22 and 0.33 mm respectively. It is found that the crushing strength of aluminium can with maximum thickness of aluminium can is maximum. Fig -8: Crushing strength variation with mass of Crusher It is quite evident from the analysis that as the mass of the crusher increases the crushing strength of the aluminium can decreases that is the load required to totally crush the sample of 0.33 mm decreases drastically. This is mainly because of the effect of inertia of crusher in dynamic loading. In crush test kinetic energy also becomes very important parameter thus effect of mass is quite evident. 5. CONCLUSIONS Fig -7: Crushing strength variation of each sample It is also quite evident from the figure that as the thickness of the sheet increases the crushing strength of aluminium cans also increases. In this analysis mass and velocity of the crusher is kept constant and equal to 1 kg and 1 m/s respectively. Various parameters affecting the crush strength of the aluminium can is evaluated using ABAQUS It is found that the thickness of sheet effect in direct proportion with the buckling strength or maximum load carrying capacity. In the same way crushing strength of the aluminium can also increases with increase in the thickness of sheet. But it is well known fact that with the increase in thickness material required and cost incurred also increases so the designer has to basically decide a thickness keeping this in mind. The effect of mass of crusher on crushing strength is also evaluated. It is found that with increase in mass the crushing strength of the aluminium can reduces. REFERENCES [1] F. Belblidia,T.N. Croft, S.J. Hardy, V. Shakespeare, R. Chambers, Simulation based aerosol can design under 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Journal Page 3084

pressure and buckling loads and comparison with experimental trials, Materials and Design, 2013, pp. 214 224.

0 0 8, pp. 347 352. [3] C.G. Foster, Measurement of Radial Deformations in Thin-walled Cylinders:, Experimental Mechanics, 1977, pp. 238-244. [4] J. Han, K. Yamazaki and S.

5 pressure and buckling loads and comparison with experimental trials, Materials and Design, 2013, pp [2] Luis Fernando Folle, Sergio Eglan Silveira Netto, Lirio Schaeffer, Analysis of the manufacturing process of beverage cans using aluminum alloy, Journal of materials processing technology 2 0 5, , pp [3] C.G. Foster, Measurement of Radial Deformations in Thin-walled Cylinders:, Experimental Mechanics, 1977, pp [4] J. Han, K. Yamazaki and S. Nishiyama, Optimization of the crushing characteristics of triangulated aluminum beverage cans, Structural Multi-disc Optimum 28, 2004, pp [5] J. Han, K. Yamazaki and S. Nishiyama, R Itoh, Application of structure optimization technique to aluminum beverage bottle design Structural Multi-disc Optimum 29, 2005, pp [6] J. Han, K. Yamazaki and S. Nishiyama, R Itoh, Multiobjective optimization of a two-piece aluminum beverage bottle considering tactile sensation of heat and embossing formability, Structural Multidisc Optimum 32, 2006, pp [7] E. Ceretti, A. Attanasio, A. Fiorentino, L. Giorleo, C. Giardini, Aluminium can shaping by hydroforming: simulative feasibility study and prototype production, Int J Adv Manuf Technol (2013) 68: [8] Joel Courbon, Mechanical metallurgy of aluminium alloys for the beverage cans, Materials Science Forum vols , pp 17-30, Dec [9] F. Xu, X. Tian, G. Li, Experimental Study on Crashworthiness of Functionally Graded Thickness Thin-Walled Tubular Structures, Experimental Mechanics (2015) 55: [10] F. Xu, X. Tian, G. Li, Experimental Study on Crashworthiness of Functionally Graded Thickness Thin-Walled Tubular Structures, Experimental Mechanics (2015) 55: [11] Ngonidzashe Mhuruyengwe, Tawanda Mushiri, Talon Garikayi, Finite element analysis of metal food cans under axial loads and sealing pressure, Global J. of Mech., Engg. & Comp. Sciences, 2013: 3 (2), PP No [12] M.R. Hackworth, J.M. Henshaw, A pressure vessel fracture mechanics study of the aluminum beverage can, Engineering Fracture Mechanics 65, 2000, pp [13] S J Hardy, R Abdusslam, Finite element modelling of the manufacturing process for aluminium aerosol cans, Proc. IMechE Vol. 221 Part L: J. Materials: Design and Applications BIOGRAPHIES Sawant D. A. borned in Pachora, situated in Maharashtra India in year He completed his high school education from St. Xavier's English Medium School in Manmad. He is graduated in mechanical Engineering from S.N.D.C.O.Engineering and Research Center Yeola. Now persuing Master degree in Design branch from S.N.D.C.O. Engineering and Research Center yeola. As his interest is towards design and development, He had shown his Skill in design field. He had done two project in Design field. The First project is "Multiutility unit for Microfinishing, Filter Cleaning, Ceiving and Grinding by Forced Vibration Effect. This project was showcased in DIPEX It was well appreciated by all. Second Project is "Vibratory Super Finishing unit". This project also Displayed in DIPEX Deepak Has also Presented Paper on the topic" Structural Analysis and Design Optimization of Handle Bar Assembly of motor" in year 2016, are organized by International conference on immerging trends and research in engineering. Dr. Venkatesh M. A. received B.E in Mechanical. and M.Tech. in production, & Ph.D. in Mechanical. He has been working asprincipal of S.N.D.C.O.E &R.C, Yeola, Maharashtra. He has 30 years of teaching experience. He has published 10 national papers and 5 international paper. 2016, IRJET Impact Factor value: 4.45 ISO 9001:2008 Certified Journal Page 3085

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