It’swell basic thewhichbracketbytheimprovementwithinvibrationmanagementisachieveddeterminantthenaturalfrequencyoftheenginesystemwellbelowthebandwithinexcitationexhibitsmostofwaveenergy.
Optimization of Engine Mounting Bracket of Tata Ace Mini Truck Shilpee Ghose1 , Prof. P. R. Shinde2
Keywords Optimization, Bracket, Fusion 360
Abstract Engine mounts haveniceimpacton the noise and formodificationthefactorspurpose.resultstodifferentbracketfailureWithplanningmadearepackageThenengineInofpackagetheandmeasureimportantfrequencyseriousfailureVibrationBracketThisoftovibrationharshness(NVH)characteristicandneedsfaceuptomassivelevelsofvibrationbecausethecharacteroftheemploymentofthemachine.workfocusesonstyleofEngineMountingforTATAACEminitruck.StaticandanalysisareperformedonthemodelandmodesareknownStyleiterationstudyareintroublethebettermentofmountlifebyimprovementthemostobjectivesoftheprojectsquaretostyleandanalyzestructuralfrequenciesstressesontheenginemounting,andtovalidatesoftwareresultsvictimizationFFTanalyzertestingelementthisprojectwearegoingtobecomingupwiththemountingbracketforTataACEminitruck.3Dmodelvictimizationmodelingsoftwareofmountingbracketarecreated.Thenwegoingtobeperformingartsstatic,modalandvibrationanalysisonthebrackettoverifytheandforlocatingoutthefailuremodes.repetitiousstylestudywearegoingtoimprovemodesandnaturalfrequenciesofthevictimizationtotallystyleparameters.ThenwearegoingchoosethemosteffectivesuitedstylefromFEAfortheimprovementofvibrationSortingoutthecausesandcontributorywithinfailurediscoveredwithinthecurrentstyle,withinthecurrentbracketimprovementofwavefailureperformance.
1Shilpee Ghose, P. G. Student (Dept of. Design Engineering), Siddhant College of Engineering, SPPU, Pune, 2Prof. P. R. Shinde, Mechanical Dept, Siddhant College of Engineering, Pune
It’s reactiontraincausedvalveshuttingforcesmotion;pistonydamperforcesfollows:exceedinglyrelevantGenerally,inthewholeunitthecanhasenhasbracketforanautomotive.Assuch,enginebracketbeendesignedasaframeworktosupportgine.Vibrationsandfatigueofengine,bracketbeenceaselesslyaprioritywhichcausestructuralfailureifensuingvibrationsandstressesareasevereandexcessive.Prolongedexposuretobodyvibrationwithinoperatingatmospheremightcausefatigueandsomecasesitdamagestheautomotivetheforemostnecessaryvibrationexcitationsinanautomotiveengineisknownascombustionforce;mainbearingreactiontogetherwithmassforcesoperateandregulatorwhirling,changedbthefrontenddamper;aspectforcestogetherwithsecondaryrotatingshaftbearingreactiontogetherwithmassforces,gapandimpactsandbearingimpacts;gapandshuttingimpacts;valvetrainforcesbychain/beltmovementorgeardrive;gearforceswithinthetransmission;drivetrainforcesandmoments.
knownfrom
It’s
I. INTRODUCTION: Engineis that themost vitalelementsof a road vehiclelikeautomotive. High performance sportsautomotivehas their engine supported by severalbeenlookworkbracket.Itplaysacrucialroleinupthecomfort&atmosphereofanautomotiveTheimprovementofenginebracketsystemhasthetopicofintenseinterestforyears.
Non linear vibration theory;
during thiscontext,the eventof engine bracketwillbuildthe engine International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 02 | Feb 2022 www.irjet.net p-ISSN: 2395-0072 *** © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page919
necessarytostylecorrectengine
| Feb
Fig. 1: mounting Bracket of Car II. LITERATURE REVIEW Mallikarjun B Patil et.al [1]conferredtheiranalysison
massof caratan equivalenttime enhance the performance.
Issue:
and Natural Frequencyoptimizationof Engine Mounting Bracket.”during
“FinitepartAnalysis thispaper the author says thatgiftautomotive market automotiveincreasevehicle.requirementoffueleconomicalandvalueeffectiveThissuccessivelygiventhetosimpleruseofmaterialsforelementswhichmightscalebackthe
demands lowvalueand lightweightweightpartto fulfillthe
reduction of vehicle’s engine mounting bracketvictimizationdiffering typesof materials.The mostparameterthought offor variationwithin thebehavior of the bracket is material variations.For variousmaterials, the stressesarecalculated and compared to arrive forthe simplestmodelunderneathprescribed conditions.Within themethodof (IRJET) 2395-0056 09 02 2022 www.irjet.net 2395-0072 value: 9001:2008
capable ofinterestingvibration. Automotive engine mounting systemshouldsatisfythe thevibrationdecentlocationsvehicleTheresultscomputerengOptimizingdecisivemountingoncegenerallyattaincharacteristicsavingstooverattainbracketisolation.dynamicfirsttaskslikeenginemovement,enginerigidbodybehavior,andvibrationStyleanddevelopmentofmountingthroughuseofAutodeskFusion360tothenecessitiesformountingsystem.LimitstheeventofthemountingsystemsthanksdrivabilityandNVHconsiderations,providesinstyleresources.NVHisacrucialvehiclesmotivatingtooverallclientsatisfaction.Engineismountedtothefrontsubframeandputininanexceedinglyvehicle,engineencompassesanimportanttaskinthevehiclevibrationcharacteristics.themountssysteminearlystagesofinestyleisfeasiblebyimplementationofaidedengineering(CAE)tools.CAEisanalyzedwithnonepriceyprototypes.resultsiswonttooutlinestrategyforthemountsystemandoptimizetheandthereforetheratesofmounts.Amountingsystemseparatesengineinputfromthevehiclebodyandsuppressimpactofroadinputstothevehiclepassengers.
Reducing weightprovidesmulti disciplinary challengeslikestrength, stiffness, M.theapprox.burdenR15.0.resultsfabriclookfinishedbracketthisandofkeepingVibrationsstressesthesethereducingmountingthesetheHarshnessfatiguelifeandNVHdemand.Noise,Vibrationandarethemostparametersthatincreasediscomforttovehiclerideandareoriginatedfromtheengine.TheenginebracketplaysthenecessaryroleinNVHandwillincreasecomfort.Becausebracketssupportstotheengineandareexposedtothehighvibrations,forcesand(staticinadditionasdynamic).areoftenreducedordissipatedandthestressesunderneaththeplannedlevelsafetyareoftendonebycarefulstyle,analysischoosingmaterialofbrackets.DuringpaperthemodalanalysisofenginemountingisbyvictimizationANSYSthirteen.0.Theofthebracketisunbrokensamehowevertheismodifiedtocarbonfibersfromsteel.TheweregeneratedbyvictimizationANSYSWiththeprojectednewmaterialtheofthebracketisreducedbyseventyfifthandthereforestressesarewithinthepermissiblestresslevel.V.AdityaNag
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Engine
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“MaterialchoiceandprocessAnalysis on DOHC V16 Engine’s Mounting MultiphysicsBracketvictimizationCOMSOLpackage .”during thispaper experimentburdenmainfinitestudyconsequencestheMotorvibrationstaskofstructureautomotiveforcesvibtheanalyzershavetoldthatreductionoftheenginerationandthereforethedynamicsendingfromenginetotheanatomicalhascontinuouslybeenacrucialapartautomotiveresearch.Automobilesectorfacetheofmakingamechanismtosoakuptheseandsupplyasleekride.TheusageofMountsisthatbestanswerformoisteningtheofvibrationsandoscillations.Thisdealswiththefabricchoiceandpartanalysisfortheengineaccentpart.Thisobjectiveoftheanalysisistoattenuatetheofthemountbracket.Thisconjointlydealswithoverallweight
on“FinitecomponentAnalysisofEngineMounting Bracket.”Theresearcherssaythatengineisonein allthe foremostnecessaryelementsof a road vehiclelikeautomotive. High performance sportsautomotivehas their engine supported by intenseengine&bracket.ItplaysacrucialroleinrisingthecomfortworksettingofanautomotiveTheadvanceofbracketsystemhasbeenthetopicofinterestforseveralyears.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 02 | Feb 2022 www.irjet.net p-ISSN: 2395-0072 2022, IRJET Impact Factor value: 7.529 ISO 9001:2008
It’sa bigstudywhich needsin depth investigationto graspthe structural characteristics and its A.frequencyaondynamicbehavior.ThispaperpresentsandfocusessomeFEAofatypicalenginebracketofautomobilearegoingtobedisbursedandnaturalaregoingtobedetermined.S.Adkineconferred the work on “Design and Analysis of Engine Mounting BracketvictimizationANSYS Tool.”during thispaper the author says that engine mounting bracket playsterriblyvitalrole in reducing vibration, noise and harshness causedbecause
It’snecessaryto stylecorrectengine bracket for anautomotive. As such, the engine mounting bracket has been designed as a framework to support engine. Fatigue of engine bracket has beenunceasinglya prioritywhich canresult instructural failure if theensuingstressesarea unitsevere and excessive. Excessive exposure to whole body stresseswithin theoperatingsettingcouldresult infatigue and in some cases it damages theautomotive. Optimizing the mounts system in early stages oftrainstyleis feasibleby computer aided engineering tools. CAE resultsare oftenanalyzedwith nonepriceyprototypes. The resultsthought abouttooutlinestrategy for the vehicle mount system and optimize the locationsand therefore therates of mounts. Monali Deshmukh et.al [6] submittedanalysispaper on “Analysis andimprovementof Engine Mounting Bracket.”during thiswork the authorssamethat the engine mounting playsa crucialrole in
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simulation,initialthe CAD modelis formedvictimizationCATIA V16 tool. The modelare going to beforeignto Consul Multiphysicspackageforperforming artsFEA on the model forappropriateloading conditions and constraints. The results obtainedareused foranalysisof bestappropriatematerial for the engine’s mounting bracketvictimizationthe D.F.M.A. methodology. A. S. Adkine et.al [3] submitted their work on “Static Behavior of Engine Mounting Bracket.”during thisworkan endeavorwascreatedto investigatethe engine mounting bracket.Styleincludes the modeling of the engine mounting brackets by takingunder considerationall packaging constraints. Analysis includes Static Analysis of engine mounting bracket.The mostpurpose of this study isto investigatethe natural frequency of by analyticallyand thrudeveloping the model and self excitation frequency of engine bracket.An endeavorwascreatedto examinewhether or notthe natural frequency of engine mounting bracketis a smaller amountthan self excitation frequency of engine bracket.Thusthis work is carried byvictimizationERW 1, ERW 2,metalandatomic number 12alloys for the Umeshstressesenginemountbracket.Theresultsareanalyzedforanddeformations.S.Ghorpadeet.al[4]conferredtheirwork
ofengine andthereforehasterriblyeffective role
N.fornumberofmay12oftenthenumberof1,lookwerethanstresscircularfrequencybracketpresentoutofbyforinupvehiclecomfort.ThiscurrentarticleaccountstheinvestigationofenginemountingbracketvictimizationANSYS.Staticandmodalanalysisenginemountingbracketwaswipedordertoanalyzewhetherornotthenaturalfrequencyofenginemountingislessthanthatofselfexcitationofbracket.Itabsolutelywasfoundthatcrosssectionhavingelicited128.47MPaisadditionalreliablesq.crosssection.Theresultsanalyzedforstressesanddeformations.ThewastestedforvariousmaterialslikeERWatomicnumber12andERW3atthesidesuitablenessoffabricStresseselicitedinatomic12bracketweresixtyfour.07MPawithdeformationofone.20mm.Itareassumedthatatomicnumberbracketsarecorrosionresistantandbethoughtoffordesiredapplication.StiffnessERW3materialwasfoundhigherthanatomic12andmaybeusedneededapplication.S.Vele,N.K.Kamble,Dr.Et.al[7]giventhework
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on “FinitepartAnalysis and Natural Frequencyoptimizationof Engine Bracket.” Theyaforementionedthat the automotive engine mounting systemsarevitalbecause oftotally differentaspectsof carperformance. Early in stressesinbeenengine.bracketnottoimprovementoftheenginemountingsystemoughtbequicklycheckedandexactlyanalyzed,whilesampleofavehicleauthorization.EnginehasbeenstyleasaframeworktosupportFatigueandvibrationofenginebrackethasincessantlyaprioritywhichcanresultstructuralfailureiftheensuingvibrationandaresevereandexcessive.
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reducing the noise, harshness and vibrations
TableNo.1.0Specification
5. To select the best suited design from FEA results for the optimization of vibration purpose.
III. OBJECTIVES OF THE PROJECT
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 02 | Feb 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page922 1. To design and model of engine mounting analyzer4.for3.on2.bracketforTATAACEusing3Dmodelingtool.Toperformstatic,dynamicandmodalanalysisthedesignedbracket.Tooptimizethedesignofthemountingbracketweightreduction.TovalidatethesoftwareresultsusingFFTtestingofcomponent.
V. PROBLEM STATEMENT
Most of the engine mounting bracket for the four wheeler engines is designed with Mild Steel material and with conventional standard shape and dimensions. In this study focus will be on designing the alternate Engine mounting bracket for the TATA ACE engine using finite element analysis technique and weight reduction in the current design needs to be achieved.
VI. THEORETICAL ANALYSIS
6. To manufacture the optimized bracket as per modified parameters.
IV. METHODOLOGY OF THE PROPOSED WORK
4. Iterative design study to improve failure modes and natural frequencies of the bracket using different design parameters.
“StructuralsturdinessAnalysis oftrainMounting Bracket.”the studentssay that structural analysis is performedto resultsbolttheoptimized3gdifferentlibrary.fabricchosenisComsolthisfacilitytomountingtheoptimizedfatigueofgeneratedinandexaminesturdinessofnominalhalfforagivenloadsupportconditions.Fortheelementtobesafe,anydomain,thestressesshouldn'texceedtheyieldstrengththefabric.However,consideringchanceoflifefailure,theelementissuchstressesgenerateddon'texceedendurancestrengthofthefabric.Theenginebracketissubjectedhundredsprimarilythankstoweightofthetrain,theunbalancedforceDuringanalysis,structuralmechanicslibraryofisemployed.TheCADmodelforeignfromCATIA®V5R21.PolyhedronisbecausethemeshingcomponentTheischosenfrom'builtin'materialsinComsolThebracketissubjectedtototallyloadingconditionslike321gweights,downwardunbalancedforceetc.andissostressesgeneratedanddeflectionofbracketisamongpermissiblelimit.Resultofpreloadsisadditionallythoughtabout.Theoftheanalysisareaunitcomparedwith
Vehicleselectedforstudy TATAAce
SameerandmaintainingbracketthecomparedmodelsdeformationsinthetermbrackettheuniqueexistingFEAdynamicresponsemountingStaticbrackets.carefullevelkeepingvibrations.andframeforrisingvehicleridecomfort.ThebracketsonthethatsupporttheengineendurehighstaticdynamicstresseslikewiseaslargequantityofThus,dissipatingthevibrationsandthestressesunderneathapredeterminedofsafetyoughttobeachievedbyplanningandanalysisofthemountKeepingthisinmindduringthispaper,Analysis,modalanalysisofengineisfinishedlikewiseasharmonicanalysisofbracketasasectionofanalysisisperformedwiththecomputercodepackageANSYSfifteen.0.Themodelisoptimizedandacompletelymodelwasprojectedtocutbacktheloadofriboftheenginemountinglikewisebecausetheharmonicresponseinofaccelerationischeckedtomakesurethatprojectedmodelwon'tendtostridentoperation.Theresultsofthestresses,andharmonicresponsefortheoftheenginemountingbracketweretoeveryalternative.Withprojectedmodeloftheenginemountingtwelve.5%weightreductionisachievedanappropriatelevelofyieldstressharmonicresponse.U.Kolteet.al[8]submittedanalysison
hyper mesh results andarea unitfound to be in bestcorrelation.
3. Perform static, modal and forced vibration analysis on the bracket to verify the design and for finding out the failure modes.
Conducting FFT analyzer test on the bracket model and comparing the results with FEA.
1. To find out-design specification for engine mounting bracket. 2. Designing the engine mounting bracket, and modeling in modeling software.
EngineType Cylinders,FourStrokes,Two702cc MaximumPower 320016HP(12KWatt)atrpm WeightVehicleKerb 885Kg WeightVehicleGross 1550Kg EngineWeight transmission151Kg+49Kg(Partofweight) WeightTotalDesign 200Kg(2000NApprox.) arerequirementstherequirement,effecteithergeometricalselectionOptimumOptimumMaterialBracketDesignforthicknessselectionforbracketMaterialSelectionbyJohnsonMethod:designofmechanicalelementistheofmaterialandvaluesforindependentparameterswithexplicitobjectiveofminimizingmostsignificantundesirableormaximizingamostsignificantfunctionalmakinginthedesignprocedurethatmechanicalelementsatisfiesotherfunctionalandthatotherundesirableeffectskeptwithintolerablelimits. Primary Design Equation (P.D.E): Weight(W)perunitlength=weightdensity × W=volumeofplatew ×(b×Ɩ×t)……………………(1) Subsidiary design equation (S.D.E): Bendingstress=F×L×Yb12t3………………(2) tBendingPutY=t2stress=6×F×Lb×t22=6×F×Lb× σ t=√6×F×Lb×σ……………………....(3) Limitequation Σb≤SbNf……………………....(4) W=CombiningS.D.EwithP.D.Eweget,w × b × Ɩ ×√6×F×Lb×σ .(5) Therefore, Wα1√�� Soweightwillbeminimumifbendingstresswill bemaximumi.e.σbwillbeinitsupperlimit. i.e Σb=SbNf=0.6SyNf Byputtingσb=0.6SyNfineq.(5) W=3.162√F×L×b×��√���� Thisisthedesiredequation: 3.162Byconsidering, √F×L×btermconstantsayK,weget, W=K��√Sy Table 2.0 Different material properties no.Sr. Material DensityWeightW StrengthYieldS y w/√Sy 1 MS(AISI1018) 77204.7 370 4013.68123 2 SS310 78480 205 5481.28096 3 SS309 78480 310 4457.36448 4 steelTool 22106.6 600 3147.86 From above equation it is possible to evaluate weight density of various steels which directly affects the weight of material. Among above tabulated results, weight factor ( ��√����) for tool steel is lowerthanany othertypeofsteel soitis justified that alloy steel is optimal material for MaterialMechanicalasselectmanufacturingbracket.ButifweconsidercostofthetoolsteelandprocessesareveryhardwewillthenextbestoptionwhichisMSAISI1018thematerialforthebracket.PropertiesformaterialMSAISI1018 Syt 370MPa Sut 440MPa Elongation 15% ModulusofElasticity(E) 205GPa Poisson’sRatio(μ) 0.29 Consideringbendingformula, ����=���� Now,calculatingbendingmoment ����=��×�� =70000������ Moment of inertia of minimum area at two hole section, ��=������������ 2(��ℎ������) =��×��312−2(��×��312) ��=3.67��3 PositionofNeutralAxis,��=��2 Nowputtingvalueinbendingequation, ����=������ ∴��2=27.67 ∴�� CheckingSelecting=5.26mmnextgradeofthicknessas6mmbracketforshearstress International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 02 | Feb 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page923
The finitecomponenttechniquemay be anumerical technique for gainingAssociate in NursingapproximateAssociate in Nursingswer tothe matterby representingthe articleby an assembly of rods, plates, blocks, bricks. Finitecomponentanalysismay be soatechniqueofdetermination,sometimesor,sureissuesinengineering and science. It’s usedchieflyforissuesthatnoactuala nswer,utter ablein some mathematicalkind,is obtainable. As such,it'sa numericalinstead ofAssociate in (Hookean)goodheatphenomena,torunsupplytacticcomputationengineeringtoengineeringindeed,Oneanutbeathepropertyofinimportant,ofsortnursinganalyticaltechnique.Strategiesofthisarerequiredasaresultanalyticalstrategiescannotaddressthesophisticatedissuesthataremetwithengineering.forinstance,engineeringstrengthmaterialsorthemathematicaltheoryofphysicalareoftenwonttocalculateanalyticallystressesandstrainsduringabentm,howeverneitherareterriblywinningfindowhat'shappeningpartlyofautomotivesuspensionthroughoutcornering.amongsttheprimaryapplicationsofFEAwas,toseekoutthestressesandstrainsinpartsbeneathload.FEA,onceappliedassociateinnursingrealisticmodelofanpart,needsavastquantityofandalsothedevelopmentofthehasreliedontheofappropriatedigitalcomputersforittoon.thetacticiscurrentlyappliedissuesinvolvingagoodvaryoftogetherwithvibrations,conductivity,mechanicsandphysics,andavaryoffabricproperties,likelinear-elasticbehaviorandbehaviorinvolving
Fixed holes are highlighted with locks and blue stressatofVonresultsremotelyabovecolorhighlightstheloadingattachmentareainthefigure.Totalof1000Nforceappliedtothebracket.Belowaregiventheoftheanalysisperformedonthebracket.misesstressplotshowsthemaximumstress221.5MPawhichisduetostressconcentrationthefixingboundarycondition.Wecanseeintheplotthatmaximumstressintheareaisnot
atMinimumareawillbeatmaximumstressanditistheholesection, ��������=(60×6)−2(8×6) =264���� Calculating2shearstressinducedinplate,��=���������� =7.58��/����2 material,Nowcalculatingallowableshearstressforbracket ��������=0.5������ =175=0.5×370 ��/����2 ��≤�������� VII. FINITE ELEMENT ANALYSIS deviation fromlaw(for example,physical propertyor rubber elasticity). Model of the mounting bracket for engineis formedexploitationmodellingcodeCATIA as locationforcemeshingasAutodeskModelshownwithintheimagebelowFig.1.1:CADModelforEnginemountingbracketshowninthefigureaboveisimportedintheFusion360software.Bracketismodelledasolid.Standardsizeof1mmisusedforthefineandgoodresultsofFEAanalysis.Remoteof1000Nisappliedremotelytothemountingoftheengine.Fig.1.2:BoundaryConditionsoftheStaticAnalysis
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Nowenginemountingbracketbaselinemodule.Table:3.0First6naturalfrequenciestablebaselineModeNo.NaturalFrequency(Hz)Steelbracket19092196933044439945741569763wewillusetheoptimizationtechnique for
optimizationoptimizationmodelfindingthepossibilityofweightoptimization.Theandmeshingofthemodelissimilarinthemodule.Onlyonethingaddedisthesettings. 2395-0056 09 2395-0072
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frequenciesshapegivenshapesisAfterFEAsavewhichmaximumstressThiswhichareacrossing221.5MPalimitasthereisnosignificantaboveorinthegreencolorbandofcontourrepresentstresseshigherthan221.5MPa.Fig.1.3:vonMisesstressplotplotshowsthestressdistributionofhighisreallylocalandaveragestressnearthestressregioncrosssectionis96.79MPameansdesignissafeanditcanbeiteratedtosomematerialbyredesigningit.ResultsModalAnalysisstaticanalysisonthebracketmodalanalysisperformedonthebrackettofindoutmodeandmodalfrequenciesofthebracketattheboundaryconditionsoffixing.Firstmodeisplottedandlistoffirst6naturalisgiveninthetable.Fig.1.4:Boundaryconditionforthemodalanalysis Baselinemodel’sfirstmodeshapeplotisshownin theimagebelow.
theModeFig:1.5:Mode1@baselinemodel909Hzshapeshowsthatmodeisduetoloadinginverticaldirection.Enginehasmaximumspeed of 6000 RPM which will say that engine’s second order frequency will not cross value of 200 RPS that is 200 Hz. Modal frequency of the bracket is much higher for getting affected by engine load variations. Which shows us that thereis scope of removingmaterialandstillwon’taffectvibrational life of the engine mounting bracket. Table below shows the list of first 6 modal frequencies of the
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Fig.1.9:Sketchforiteration2 In the above image, the maximum stress value is IterationlooksbasedNowanotherMpa.stressconcentrationshownas212.1Mpa.Thisvalueisduetothestressintheregion.Ifweseethevalueofintheadjacentelement,itistoolowi.e.96.66Thereforethedesignissafe.Nowwetryforiterationwithmorematerialremoval.wecutthematerialfromthebasicmodelontheaboveshownsketch.Sothemodelliketheimageshownbelow.Fig.2.0:Modelforiteration2Fig.2.1:VonMisesstressplotforiteration23:usedhorizontalIterationthematerialremoved.TheabovefigureshowstheloadcriticalitypathandalsotheareasfromwherethematerialcanbeNowweperformiterationstoremovefromthebasiccurrentmodelandsolveiterationfortheloadandboundaryconditions.1:Makinga25mmholeonthecomponentofthebracket.Thesketchtomaketheholeisasshownbelow.
bracketMakingIterationFig.Fig.1.6:TheoptimizedmodelandtheloadcriticalitypathFig.1.7:Sketchforiteration1,25mmhole1.8:VonMisesstressplotforiteration12:acutinthehorizontalcomponentoftheasshowninthebelowsketch.
Fig.2.5:Modelforiteration4
Fig.2.3:VonMisesStressPlotforiteration3
In the above image, the maximum stress value is
ModalanotherMpa.stressconcentrshownas221.4Mpa.Thisvalueisduetothestressationintheregion.Ifweseethevalueofintheadjacentelement,itistoolowi.e.89.4Thereforethedesignissafe.Nowwetryforiterationwithmorematerialremoval.Analysisforiteration4Fig.2.7:Boundaryconditionsformodalanalysisforiteration4
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Fig.2.6:VonMisesStressplotforiteration4 In the above image, the maximum stress value is
Fig.2.2:Modelforiteration3
IterationanotherMpa.stressconcentrationshownas247Mpa.Thisvalueisduetothestressintheregion.Ifweseethevalueofintheadjacentelement,itistoolowi.e.90.77Thereforethedesignissafe.Nowwetryforiterationwithmorematerialremoval.4:Fig.2.4:Sketchforremovingmaterialfromhorizontalcomponent
theModeFig.2.8:ModalAnalysisplotfor1stmode@1702Hzshapeshowsthatmodeisduetoloadinginverticaldirection.Enginehasmaximumspeed of 6000 RPM which will say that engine’s second order frequency will not cross value of 200 RPS that is 200 Hz. Modal frequency of the bracket is much higher for getting affected by engine load variations. Which shows us that thereis scope of removingmaterialandstillwon’taffectvibrational life of the engine mounting bracket. Table below shows the list of first 6 modal frequencies of the iterationmanufacturingmodalTheenginemountingbracketbaselinemodule.Table:3.0First6naturalfrequenciestableforiteration4ModeNo.NaturalFrequency(Hz)Steelbracket11702231383502745731511340613740designforiteration4issafeinstaticaswellasanalysisandthereforewecangoforasperthechangessuggestedinthe4.
VIII. MANUFACTURING developdevelopthicknesdonemildForthemanufacturingofenginemountingbracketsteelmaterialisused.Themanufacturingisonthelasercuttingmachineforthat6mmssheetisusedandfromthelastiterationlengthofbracketiscalculated.Fromlengthdraftingisdoneforlasercutting drawing, after laser cutting operation bending operationisdone.Fig.2.7:LaserCuttingFig.2.8:BendingOperation IX. EXPERIMENTAL VALIDATION Fig.3.0:compressionloading International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 02 | Feb 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page928
The maximum weight reduction is obtained in the fourth iteration i.e. 18%.
3. Static Behaviors of Engine Mounting
7. InBracket,ElementN.S.Vele,N.K.Kamble,Dr.S.V.JoshiFiniteAnalysisofEngineMountInternationalJournalofResearchAdvanceTechnology(IJRAT),201314.
XI. CONCLUSION
2. M.V. Aditya Nag, “Material Selection and Computational Analysis on DOHC V16 Engine’sMountingBracketUsingCOMSOL Multiphysics Software”, COMSOL ConferenceBangalore,2012.
4. Finite Element Analysis And Natural Frequency Optimization Of Engine
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Fig. 3.1: Load vs. Displacement X. RESULT From the above iterations done on the Finite bracket.forElementAnalysis,wehavegotthefollowingresultstheweightreductionoftheenginemountingIterationMass(gms)%ReductioninmassBasicmodel364Iteration13416%Iteration23358%Iteration33309%Iteration429918%
1. MallikarjunBPatil,Prof.S.SKelkar,“Finite Element Analysis and Natural Frequency Optimization of Engine Mounting Bracket”, International Engineering ResearchJournalPageNo981 989.
8. Sameer U. Kolte, David Neihguk, and Abhinav Prasad, Structural Durability DOI:10.13140/RG.2.1.1414.6722OctoberAnalysisofPowertrainMountingBracket,2013
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5. DecemberDOI:10.13140/RG.2.1.4946.4406,MountingA.S.Adkine,DesignandAnalysisofEngineBracketusingANSYSTool,2015.
4,EngineeringAdvancedOverikar,Bracket,A.S.Adkine,V.S.Kathavate,G.P.S.N.Doijode,InternationalResearchJournalinScience,andTechnologyVol.2,IssueApril2015.
2231IndustrialInternationalVinayBracket,UmeshS.Ghorpade,D.S.Chavan,Patil&MahendraGaikwad,JournalofMechanicalandEngineering(IJMIE)ISSNNo.6477,Vol2,Iss3,2012.
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UniversalfourthmountingThereforewithoutreducedtotalgraWeightoftheoptimizedbracketisobservedas299mswhichwas364gramsinthebasicpart.Soof65grammassisreduced,18%weightisfromthetotalweightofthebracketaffectingtheloadcarryingcapacity.wehavemanufacturedtheenginebracketasperthedimensionsoftheiterationandsuccessfullytesteditonTestingMachine.
6. Monali Deshmukh, Prof. K R Sontakke, Analysis and Optimization of Engine 3.05.(IJSER),ScientificMountingBracket,InternationalJournalofEngineeringandResearch23473878,ImpactFactor(2014):
12. V.Ratna Kiran, M.V. Aditya Nag, “Design optimizationforenginemountbracketfor V6 engine”, Proceedings of 2nd International Conference on Advances in India,MechanicalandBuildingSciences,V.I.T.U.,ppno814819.