Study of grid dependency using a bevel gear simulation   A grid (or mesh) dependency test allows the engineer to estimate the optimal element sizing used in meshing to arrive at the desired solution without any further refinement required. This type of test is primarily concerned with the conservation of computational…

Effect of Friction on Cam-Piston Mechanism Kedar Kapadnis   Geometry setup and cleaning Fig 1 The above piston-cam mechanism consists of a follower (green) translating the groove on the cam and moving the pistons in the barrel up and down. The cam and barrel are converted to rigid bodies (Stiffness behavior) since…

Material Selection – Motion transfer using universal joints (Transient structural analysis)   Geometry setup   This assemble consists of 5 parts – the front sprocket, two pins for universal joints, a joint shoulder and a spring end. The goal of this simulation is to observe the deformation and stress…

Final Assembly - Chopper   Gas tank   The shape of the gas tank was produced using surface extrudes, sweeps, boundary surfaces and complex curves; the final enclosure was knitted and thickened to convert into a solid and fillets and shell were added    The final assembly was designed using basic and…

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Non-linear structural analysis - Wire bending Kedar Kapadnis   Fig: Initial Geometry The lever rotates around the central (common) axis of the itself and the wheel and the cylindrical peg in contact with the wire bends the wire against the wheel   Fig: Mesh development Sizing/Method Patch conforming method (global)…

Verification of Weld Joints for wall bracket made with two different steels Kedar Kapadnis   Case 1 – Stainless steel used for plates, ribs and weldments   Fig: Initial geometry   Fig: Mesh model   Sizing Body sizing – the big and small plate are body sized – 7.0mm Nodes: 25305, Elements:…

Deformation of copper sheet under rolling   Fig: Initial geometry   Fig: Mesh development   Sizing Body sizing – workpiece – 4.0mm Contacts – Frictional contact between wheels and either side of workpiece Coefficient of friction = 0.2 between all contact bodies A 14-step displacement from…

Effect of a Tantalum bullet piercing through a bucket (material comparison)   This explicit dynamic simulation consists of a tantalum bullet exhibiting rigid body behavior penetrating through a metallic bucket of uniform thickness at two locations and the effects are registered for three different non-linear materials…

Worm gear simulation – Transient structural analysis   Geometry setup Fig 1: Geometry clean-up   This assemble consists of 2 parts – the worm gear and the wheel. The wheel is split by a mid-plane to conserve element usage and computational time. Here, the worm is assigned a specified number of rotations…

The tension test specimen would experience a temperature surge at the point of fracture when pulled and broken rapidly. Therefore, the temperature would be the highest at the fracture point.   This is due to the fact that the fracture point experiences the highest change in stress concentration and thus undergoes…

Compressive tests require higher capacity machines due to higher compressive strengths compared to tensile strengths.   In the case of general materials, the specimen goes under permanent deformation beyond its elastic limit while under tension. This leads to the creation of voids within the atomic/molecular structure…

Chain  Oil tank Pedal

Planing Operation Analysis on a Carbon steel (1006) workpiece   Linear planning is associated with shearing off a top layer of a workpiece/uneven surface to plane or flatten the top. In this simulation, the effect of two different velocities is examined on a workpiece to study its after-effects.   Geometry Tool…

Frontal crash simulation of car body   This explicit dynamic simulation consists of a half-model of a car body (assigned non-linear behavior to observe permanent deformation) crashing into a rigid wall for a given displacement in a fixed time period and parametrizing body thickness to observe variations in the outcomes…

Chassis: Mainframe of the chopper; designed to support front fork, engine, rear wheel, gas tank and seating Modeled using extruded bosses and cuts, swept projected curves, revolves and fillets   Engine: Contains 2 cylinders, air intake, starter motor, flywheel, chain rotors, spark plug inlets and exhausts Modeled…

Observing Plastic Deformation on a flat plate due to external pressure Kedar Kapadnis   Geometry setup and cleaning Fig 1 The model is reduced to the above size after identifying planes of symmetry in order to reduce meshing size as well as computation time and power consumption Meshing Fig 2 (Standard meshing –…

Rear Wheel Front Fork

Tensile & Torsional test on a Carbon steel (1006) specimen Fig: Test Specimen geometry       Fig: Torsional test mesh                 Fig: Tensile test mesh Tension Test mesh parameters Mesh method: Patch conforming – tetrahedrons (on complete body)…

Rear Fender   Transmission belt   Kickstand   Front fender