MDP 10604

COMPUTER
AIDED
ENGINEERING
LECTURER:
DR. ING. NG CHUAN HUAT
GROUP PROJECT
Optimization of Student Chair Design Using Finite
Element Analysis (FEA)
PREPARED BY:
1) WAN SHAIFUL HASRIZAM BIN WAN MUDA GD120142
2) MOHD AZLI BIN IDRIS
GD120125
) MOHD HAZRUWADI BIN HUSAIN
GD12012!
4) HAZILA BINTI NAYAN
GD12012
ABSTRACT
This paper represents detail analytical simulation procedures of Finite Element
Analysis (FEA) used in order to design student chair which maximize the usage
of material properties, in order to highly reduce the material cost in the
manufacturing process. In order to deelop ade!uate and productie
procedures, finite element model were created lying on the important concept of
concentrated stress and safety factor on the design. The effectieness of FEA
techni!ue was represented "y the Inentor software. #esult o"tained from the
FEA proide promising data and procedures deeloped were used to deise
new high performance student chair with less effort "ut high accuracy. $ey
areas of optimization are to reduce the material used on the low region area of
%on &ises stress distri"ution and redesign the regions of the high stresses. The
results of the design optimization achieed the o"'ecties and the goals
demonstrated to the manufactures that FEA techni!ue represents an efficient
and safe way in designing the student chair.
TABLE OF CONTENTS
A()T#A*T
i
+I)T ,F FI-.#E
i
+I)T ,F TA(+E
/.0 I1T#,2.*TI,1
/./ -eneral Introduction
/./.3 &anufacturing )tandards
/.3 Importance of )tudy
/.3./ Finite Element Analysis (FEA) *oncept
/.4 5ro"lem )tatement
/.4./ )ole the pro"lem of chair structural failure in
$$T& $emaman
/.4.3 5romote an FEA techni!ue in chair manufacturing
/.4 ,"'ecties of )tudy
/.6 Arrangement of the )tudy
3.0 +ITE#AT.#E #E%IE7
3./ Introduction
3.3 *ontri"utions of 5reious #esearchers in FEA
3.4 Theory *alculation
3.4./ )tress
3.4.3 %on &ises )tress
3.4.4 *yclic +oading
3.4.6 Factor of )afety
3.4.8 9ield )trength
3.6 Finite Element Analysis (FEA)
3.8 -eneral )tages of a FEA Analysis
3.8./ Initial Approach
3.8.3 )olid &odelling and &eshing (5re:processing)
3.8.4 &aterial 5roperties
3.8.6 (oundary *ondition
3.8.8 +oading Analysis and +oad *ases
3.8.; #unning the Analysis
3.8.< 5ost:processing of #esults
3.; *hair Analysis and )imulation .sing A1)9)
3.;./ &odeling
3.8.3 &aterials
3.< &yto *hair 2eelopment *ycle
4.0 &ET=,2,+,-9 > )T.2E1T) *=AI# $$T& $E&A&A1
4./ Introduction
4.3 5ro'ect Flow *hart
3.2.1 +iterature #eiew > Information and
compreshension
3.2.2 5art &odeling
3.2.3 &odel Anaiysis and )imulation
3.2.4 Interpretation and syntgesis #esult
3.2.5 Ealuation and *onclusion
LIST OF FIGURES
Figure 2.1: +oading #esult( )ource? T. (rosh and &. Arcan, 3000)
Figure 2.2: )tress tensor
Figure 2.3: %on &ises )tress
Figure 2.4 : %on &ises *riterion
Figure 2.5: ):1 *ure
Figure 2.5@ 9ield )trength *riteria
Figure 2.6: *hair FEA &odel
Figure 2.7: %on &ises stress for Test 30 with <8l"f on front leg
Figure 2.8: Analysis &yto *hair
Figure 3.1: Autodest Inentor
Figure 3.2: *hair 2etail
Figure 3.3: 5arts of *hair
LIST OF TABLE
Ta!e 1.1: 7orA 5lan
Ta!e 2.1: Fo) B )trength of *omponentC+oad on component
Ta!e 3: The material
C"A#TER I
INTRO$UCTION
1.1 Ge%era! I%&r'(u)&i'%
A chair is a piece of furniture with a raised surface used to sit on,
commonly used "y one person. *hairs are most often supported "y four legs
and hae a "acA? howeer, a chair can hae three legs or could hae a different
shape. The chair is of extreme anti!uity and simplicity, although for many
centuries and indeed for thousands of years it was an article of state and dignity
rather than an article of ordinary use. The chair is still extensiely used as the
em"lem of authority in the (ritish =ouse of *ommons and in pu"lic meetings. It
was not, in fact, until the /;
th
century that it "ecame common anywhere. The
chest, the "ench and the stool were until then the ordinary used in eeryday
liing.
1.1.2 *a%u+a)&uri%g S&a%(ar(,
*hair design considers intended usage and ergonomics. In achieing the
design specification, the standards such I),, ,)=A, 1A)I and (IF&A are
"eing considered in order for the part to "e accepta"le in the industry. These
standards coering all aspects? type of chairs, specifies sta"ility, worAstation
layout, postural re!uirement, testing commercial grade and DproofE load parts
that must "e withstand.
,ccupational )afety F =ealth Administration (,)=A) defined potential
hazard and the solution for it. (usiness and Institutional Furniture
&anufacturerEs Association ((IF&A) sets industry standards for commercial:
grade furniture. It proides manufacturers and users with a common "asis for
ealuating safety, dura"ility and the structural ade!uacy of the specified
furniture. The standards define specific tests, la"oratory e!uipment to "e used,
formula to determine weight or height to use in each test, the conditions of
testing and the acceptances leels to "e used in ealuating these products. The
International ,rganization for )tandardization (I),) is an international standard:
setting "ody composed of representaties from national standard "odies. The
organization produces world:wide industrial and commercial standards. In
&alaysia, &) /<// Furniture > ,ffice *hair is a standard series of chair. &)
/<// consist of the following parts@
a) 5art /@ 2imensions > 2etermination of dimensions
") 5art 3@ )afety re!uirements
c) 5art 4@ )afety test methods
1.2 I-.'r&a%)e '+ S&u(/
1.2.1 Fi%i&e E!e-e%& A%a!/,i, 0FEA1 C'%)e.&
The importance of the study is to analyze the stress for each point on the
chair. To inestigate how the stress distri"ution are effected "y the loading and
constraint distri"ution using finite element analysis (FEA) techni!ue. The
manufacturing need of the chair is to minimize weight, materials and cost
factors. Excess load or oerloading may cause structural failure, and hence
possi"ility should "e either considered in the design or strictly controlled.
For more complex design, detailed simulation is in shown as result.
,utput from the analysis included stress distri"utions, giing engineers insight
into each design so they could select and refine the configuration that worAed
"est. A ariety of specializations under the mechanical engineering discipline
such as aeronautical, "iomechanical and automotie industries all commonly
utilize the "enefits of integrated FEA in the design and deelopment of their
products, where hand calculation is ery complicated. *urrently, seeral modern
FEA pacAages include specific components such as thermal, electromagnetic,
fluid and structural worAing enironments.
FEA is a computer simulation techni!ue used in engineering analysis. It
uses a numerical techni!ue called the finite element method (FE&). FEA allows
entire design to "e constructed, refined and optimized "efore the design is
actually manufactured. This powerful design tool has significantly improed "oth
the standard of engineering designs and the methodology of the design process
in many industrial applications. The introduction of FEA has su"stantially
decreased the time taAen to get products from concept to the production line. It
is primarily through improed initial prototype designs using FEA that the testing
and deelopment stages hae "een accelerated. In summary, the "enefits of
FEA include@ prototyping, fewer hardware prototypes, a faster and less
expensie design cycle, increased productiity and increased reenue.
In this study, we will focus on the the stress analysis of student chair for
selected model (which is used at $$T& $emaman) where weaAest point of
current design will "e identified using FEA software. 2rawing and analysis
process will "e done using *omputer Aided 2esign (*A2) software that
em"edded with analysis function. Improement in term of design and dimension
were done to reduce the stress concentration on the chair.
1.3 #r'!e- S&a&e-e%&
1.3.1 S'!2e &3e .r'!e- '+ )3air ,&ru)&ure +ai!ure i% 44T* 4e-a-a%
)tructure failure is a failure that always occurs on chair structure from
excessie of continuous cyclic or unpredicta"le loads. The optimization of chair
structure is done to resist the failure, "y reducing the stress concentration at any
point that occurs in the design analysis process "y FEA techni!ue.
1.3.2 #r'-'&e a% FEA &e)3%i5ue i% )3air -a%u+a)&uri%g
*urrently, there is lacA of chair manufacturer gets standard recognition
from )I#I&. 7e can conclude that, the manufacturer design the chair "ased on
the experiments, failures or past experience. The lacA importance of the ariety
or uni!ue loading distri"ution on chair is "eing coered easily with simple
loading estimation and calculation in the analysis.
FEA eliminates the need of su"'ect for testing, times consuming
experimentation and eliminate the difficult and expensie machine test
e!uipment. 5redicting the improement in stiffness as example proided "y
diagonal ri"s is ery difficult with classical hand calculations.
-ien these many complex and potentially conflicting re!uirements,
deeloping the trial:and:error physical testing was considered impractical
"ecause the approach is expensie, time:consuming and limits the num"er of
design alternaties to "e ealuated. Engineers needed a way to optimize the
design early in the deelopment "y inestigating a wide range of possi"ilities
early.
1.3 O6e)&i2e, '+ S&u(/
-enerally, this study is focusing on analyzing the stress distri"ution on
the chair and how to optimize the design "y FEA techni!ue. )pecifically, the
o"'ecties of the study are diided into three. There are@
a) To identify, analyze and reduce the factor of failure of chair
") To reduce the material used in designing the chair and to reduce the
manufacturing cost
c) To analyze and optimize the used of material strength property in
designing chair
1.4 Arra%ge-e%& '+ &3e S&u(/
(efore the study "egins, a good arrangement or organization of the study
must "e carried out. As the time gien for completing the study was 4 months,
so it is important to deelop a good organization of the study to maAe sure that
all information could "e gained during the study. )o, in this study a worA plan
was deeloped for gaining the oeriew of the process.
Ta!e 1.1: 7orA 5lan
C"A#TER 2
N' Ta,7
89ee7
/ 3 4 6 8 ; < G H /0 // /3
1 Brai%,&'r-i%g A%( Ti&!e Se!e)&i'%
A. Idea
(. 5ro"lem )tatement
*. ,"'ectie
2.
)election of analysis criteria F
software
2 *a%agi%g #r'6e)&
A. (acAground #esearch
(. ,"'ectie
*. )cope
2. 5ro'ect )chedule F 5lanning
3 Li&era&ure Re2ie:
A. Fundamental
(. *urrent design
*. 5reious )tudy
4 *e&3'('!'g/
A. 2rawing (*A2)
: *urrent design
: Improised design

(. Analysis (FEA)
: *urrent design
- Improised design
*. %irtualize model prototype
- Improed design
2. ,ptimization
: )tress analysis
5 $i,)u,,i'%
A. #esult ,"tain

- Improement
(. *ost estimation
6 C'%)!u,i'%
A. A"out The 5ro'ect ,"'ectie
(. A"out The #esult ,"tained
7 Re)'--e%(a&i'%
A. For Future Inestigation
(. For Improement
LITERATURE RE;IE9
2.1 I%&r'(u)&i'%
#eiew of literature is a "acAground study a"out the Anowledge and
information gained to deelop this study. The purpose of this literature reiew is
to gain a "etter understanding on the deelopment methodologies used while
deeloping a report pro'ect. #eferences, related articles and examples of
preious report hae "een searched and analyze to understand and recognize
the existing game "ased learning pacAage aaila"le in the marAet.
Inestigation and analysis of all these information are ery important to
ensure to the existing system. It will also aoid repeating and carrying the
weaAnesses of the existing application to the proposed system.
#esearch on literature reiew is to find the "est related method to
deelop new design of chair. &ost design of chair has "een deeloped to meet
the criteria specification of the chair with the situation application.
2.2 C'%&riu&i'%, '+ #re2i'u, Re,ear)3er, i% FEA
There has "een a great deal of research on stress analysis and a large
"ody of literature on FEA modelling concept has "een pu"lished in the industrial
application. The stress analysis and the optimal design for product are always
ma'or concerns in the design.
The "est literature reiew indicating the research title on T. (rosh and &.
Arcan, sureys a great deal of literature on deeloping a systematic
methodology
towards a
realistic model, of
the "odyCchair
interaction as a
tool to analyse
sitting posture
and the
cushioning
system influence on the pelisClower "acA stress deelopment.
In io measurements were performed, in order to o"tain a set of contact
module defining the "ehaiour of the soft tissues under tension during the sitting
down process. Additionally in io indention of a metal "all into the same soft
tissues during sitting was performed in order to o"tain the characteristic module.
A finite element model was deeloped for the specific analysis.
Figure 2.1: +oading #esult( )ource? T. (rosh and &. Arcan, 3000)
%alidation of the model was achieed "y comparing its results with in io
measurement of contact stresses deeloped "etween the "ody and a stiff target
seat area. +oading the model using two alternatie cushioning materials lead to
different sets of stresses within the model? as the stiffness of the seat
decreased, the peaA contact stresses, as well as the internal "ody stresses
su"stantially decreased.
2.3 T3e'r/ Ca!)u!a&i'%

2.3.1 S&re,,
In physics, stress is a measure of the internal distri"ution of force per unit
area within a "ody that "alances and reacts to the loads applied to it. )tress is a
tensor !uantity with nine terms, "ut can "e descri"ed fully "y six terms due to
symmetry. )implifying assumptions are often used to represent stress as a
ector for engineering calculations.
Figure 2.2: )tress tensor
The stress tensor Iy is defined "y the e!uation,
7here JdF/,dF3,dF4K is the force on a small area element JdA/,dA3,dA4K
where the su"scripts /,3,4 refer to x,y, and z axes respectiely and the area
ector is a ector perpendicular to the area element, with length e!ual to the
area of the element.
The stress in an axially loaded "ar is e!ual to the applied force diided "y
the "arEs area pressure. )tresses in a 3:2 or 4:2 solid are more complex and
need to "e defined more rigorously. The internal force acting on a small area dA
of a plane that passes through a point 5 can "e resoled into three components@
one normal to the plane and two parallel to the plane. The normal component
diided "y dA gies the normal stress ( usually denoted "y L). These stresses
are aerage stresses, as the area dA is finite? "ut when the area dA is allowed to
approach zero, the stresses "ecome stresses at the point 5. In general, the
stress may ary from point to point, "ut for simple cases, such as circular
cylinders with pure axial loading, the stress normal to the cross section is
constant.
)tress can occur in li!uids, gases and solids. +i!uids and gases support
normal stress (pressure), "ut flow under shear stress. )olids support "oth shear
and normal stress, with "rittle materials failing under normal stress, and plastic
or ductile materials failing under shear stress.
2.3.2 ;'% *i,e, S&re,,
%on &ises )tress, is used to estimate yield criteria for ductile materials. It
is calculated "y com"ining stresses in two or three dimensions, with the result
compared to the tensile strength of the material loaded in one dimension. %on
&ises )tress is also useful for calculating the fatigue strength. Finite element
analysis result is typically presented as %on &ises )tress.
Figure 2.3: %on &ises )tress
%on &ises )tress reduces this to a single num"er (a scalar) for the
purposes of calculating yield criteria. %on &ises )tress in three dimensions is
7here I/, I3, I4 are the principal stresses. In the case of plane stress, I4 is
zero.
Figure 2.4 : %on &ises *riterion
Applied mathematician #ichard %on &ises came up with the %on &ises
criterion in /H/4. Also Anown as the maximum distortion energy criterion,
octahedral shear stress theory or &axwell:=u"er:=encAy:on &ises theory, it is
often used to estimate the yield of ductile materials. The on &ises criterion
states that failure occurs when the energy of distortion reaches the same energy
for yieldCfailure in uniaxial tension.
2.3.3 C/)!i) L'a(i%g
*yclic load is referring to the material strength measuring the num"er of
cycles to failure. )tandard la"oratory always use to test the arious methods for
applying the cyclic load e.g. rotating "end, cantileer "end, axial push:pull and
torsion. The data are plotted in the form of a stress:num"er of cycles to failure
():1) cure. ,wing to the statistical nature of the failure, seeral specimens
hae to "e tested at each stress leel.
Figure 2.5: ):1 *ure
)ome materials, nota"ly low:car"on steels, exhi"it a flattering off at a
particular stress leel as at (a) in figure 3.4 which is referred to as the fatigue
limit is usually a"out 60M of the tensile strength. In principle, components
designed so that the applied stresses do not exceed this leel should not fail in
serice. The difficulty is a localized stress concentration may "e present or
introduced during serice which leads to initiation, despite the design stress
"eing normally "elow the safe limit. &ost materials, howeer, exhi"it a
continually falling cure as at (") and the usual indicator of fatigue strength is to
!uote the stress "elow which failure will not "e expected in less than a gien
num"er of cycles which is referred to as the endurance limit.
2.3.4 Fa)&'r '+ Sa+e&/
Factor of safety also Anown as )afety Factor is used to proide a design
margin oer the theoretical design capacity to allow for uncertainty in the design
process. The uncertainty could "e any one of a num"er of the components of
the design process including calculations, material strengths, duty and
manufacture !uality. The alue of the safety factor is related to the lacA of
confidence in the design process. Ta"le 3./ shown the suggests safety (design)
factors for elementary worA "ased on yield strength ()ource@ Nuinall F
&arsheA, 300;)
Ta!e 2.1: Fo) B )trength of *omponentC+oad on component
N'
Fa)&'r '+
Sa+e&/
A..!i)a&i'%
/ /.38 > /.8
For exceptionally relia"le materials used under controlla"le
condition and su"'ected to loads and stresses that can "e
determined with certainty > used almost inaria"ly where low
weight is a particularly important consideration
3 /.8 > 3
For well:Anown materials under reasona"ly constant enironmental
conditions, su"'ected to loads and stresses that can "e determined
readily.
4 3 > 3.8
For aerage materials operated in ordinary enironments and
su"'ected to loads and stress that can "e determines
6 3.8 > 4
For less tried materials or for "rittle materials under aerage
conditions of enironment, load and stress.
8 4 > 6
For untried materials used under aerage conditions of
enironment, load and stress.
; 4 : 6
)hould also "e used with "etter:Anown materials that are to "e
used in uncertain enironments or su"'ect to uncertain stresses.
<
#epeated loads@ the factors esta"lished in items/ to ; are
accepta"le "ut must "e applied to the endurance limit (ie. a fatigue
strength) rather than to the yield strength of the material.
G
Impact forces@ the factors gien in items 4 to ; are accepta"le, "ut
an impact factor (the a"oe dynamic magnification factor) should "e
included.
H
(rittle materials@ where the ultimate strength is used as the
theoretical maximum, the factors presented in items / to ; should
"e approximately dou"led.
/0
7here higher factors might appear desira"le, a more thorough
analysis of the pro"lem should "e undertaAen "efore deciding on
their use.
2.3.5 <ie!( S&re%g&3
9ield strength, or the yield point, is defined in engineering and materials
science as the stress at which a material "egins to plastically deform. 5rior to
the yield point the material will deform elastically and will return to its original
shape when the applied stress is remoed. ,nce the yield point is passed some
fraction of the deformation will "e permanent and non:reersi"le. $nowledge of
the yield point is ital when designing a component since it generally represents
an upper limit to the load that can "e applied. It is also important for the control
of many materials production techni!ues such as forging, rolling or pressing.
Figure 2.5@ 9ield )trength *riteria
In structural engineering, yield is the permanent plastic deformation of a
structural mem"er under stress. This is a soft failure mode which does not
normally cause catastrophic failure unless it accelerates "ucAling.
9ield criterion, often expressed as yield surface, is a hypothesis
concerning the limit of elasticity under any com"ination of stresses. There are
two interpretations of yield criterion@ one is purely mathematical in taAing a
statistical approach while other models attempt to proide a 'ustification "ased
on esta"lished physical principles. )ince stress and strain are tensor !ualities
they can "e descri"ed on the "asis of the three principal directions, in the case
of stress these are denoted "y I/, I3 and I4.
2.4 Fi%i&e E!e-e%& A%a!/,i, 0FEA1
*omputer aided Engineering analysis (*AE) is the application of
computer software in engineering to analyse the ro"ustness and performance of
components and assem"lies. It encompasses simulation, alidation and
optimization of products and manufacturing tools. The primary structural
application of *AE taAes the form of FEA.
Finite Element Analysis (FEA) is a computer simulation techni!ue used in
engineering analysis. It uses a numerical techni!ue called the finite element
method (FE&). In general, there are three phases in any computer:aided
engineering tasA. First is pre:processing defining the finite element model and
enironmental factors to "e applied to it. Follow "y analysis soler, solution of
finite element model. +ast stage is the post:processing of result using
isualization tools.
2.5 Ge%era! S&age, '+ a FEA A%a!/,i,
2.5.1 I%i&ia! A..r'a)3
The first step of performing FEA analysis is a set of models that needs to
"e constructed. The aim of the process was deelop and understand. Another
important aspect to consider in this analysis was the conergence process
related to finite element mesh re!uirement. 2ifferent approaches regarding
contact "oundary conditions and mesh density were inestigated.
2.5.2 S'!i( *'(e!!i%g a%( *e,3i%g 0#re=.r')e,,i%g1
The first step (pre:processing) in using FEA is constructing a finite
element model of the structure to "e analysed. The simplest mechanism to
achiee modelling similarity in structural analysis is to utilize *A2 models and
data "y importing that into a FEA enironment. ,nce the finite element
geometric model has "een created, a meshing procedure is used to define and
"reaA the model up into small elements. In general a finite element model is
defined "y a mesh networA, which is made up of the geometric arrangement of
elements and nodes. 1odes represent points at which features such as
displacements are calculated.
2.5.3 *a&eria! #r'.er&ie,
The material need to "e assigned according to the properties needed for
the model. The "asic materials are usually gien with the pacAage of software
used, or the different properties needed can "e add or modify easily.
2.5.4 B'u%(ar/ C'%(i&i'%
(oundary conditions are represented to the model, understanding the
contact "oundary conditions of the model with enironment to apply the
constraint needed.
2.5.5 L'a(i%g A%a!/,i, a%( L'a( Ca,e,
The next step is to consider the loads to "e applied. .nderstanding of the
directions and the magnitudes inole in the system, "ody weight or operating
load inoled.
2.5.6 Ru%%i%g &3e A%a!/,i,
The next stage of the FEA process is analysis. The FE& conducts a
series of computational procedures inoling applied forces, and the properties
of the elements which produces a model solution. )uch a structural analysis
allows the determination of effects such as deformations, strains, and stresses
which are caused "y applied structural loads such as force, pressure and
graity.
2.5.7 #',&=.r')e,,i%g '+ Re,u!&,
The results are easily sorted "y a computer. It may then "e displayed to
the engineers as a graph. This usually has little arrows and contours that are
much easier to understand. 1umerical and -raphical tools allow the precise
location of data such as stresses and deflections to "e identified. In such
graphs, colours are used to differentiate "etween the different sizes of the
alues.
2.6 C3air A%a!/,i, a%( Si-u!a&i'% U,i%g ANS<S
American 1ational )tandard for ,ffice Furnishings:-eneral:5urpose
,ffice *hairs:Tests were set forth "y the (usiness F Institutional Furniture
&anufacturerEs Association((IF&A). A1)9) is employed to simulate the (IF&A
tests to detect any potential pro"lem and proide insight into the "ehaior of the
chair and optimize the design to meet the regulation re!uirements.
2.6.1 *'(e!i%g
The modelcontains allthe structuralcomponents thatusuallyundergo
deformation during the actual tests. &iddle surfaces for the tu"es were
generated for shell elements with the thicAness.The model is shown in Figure
3.;. The aerage element size is 0.4:0.8 in
Figure 2.6: *hair FEA &odel
2.5.2 *a&eria!,
The properties of steel are used as standard for all the tu"e parts made of
steel. The material properties of the seat and "acA are polypropylene. The
properties of seat, "acA, rods and tu"es are listed in Ta"le 4
Ta!e 3: The material
The loading and "oundary conditions outlined in A1)IC(IF&A O8./:/HH4
were used for the fie tests. The goal of the initial analysis was to o"tain the
performances of the chair in the fie test simulations.
The analysis for each test started with a "aseline model@ a model which
legs thicAness are the same as line data proided. The "aseline model was
used to get an understanding of what is actually happening to the chair during
the tests. &aximum %on &ises stress is used to understand the mode and
eents of the deformation. 7e want to Aeep the &aximum %on &ises stress
"elow the material strength.
Figure 2.7: %on &ises stress for Test 30 with <8l"f on front leg
Although arying thicAness of the legs hae "een used and analyzed for
reducing the maximumstress, somehigh alues suggestsomema'or design
changes inthe structure. )ince those ma'or changes are "asicallyapproed
"ythe designer, it is important to esta"lish somenew design guideline atthisstage
of the pro'ect.
2.7 */&' C3air $e2e!'.-e%& C/)!e
The &yto *hair (designed "y $onstantin -rcic, produced "y 5lanA) went
from concept to production in 'ust oer a year. This is a remarAa"ly short
deelopment cycle for a mass produced, in'ection molded piece of furniture. To
maAe it all happen so !uicAly, the designer, manufacturer, and materials supplier
colla"orated extensiely throughout the process. Although I hae no proof to
cite, I am certain that this aggressie deelopment cycle would not hae "een
possi"le without *A2 technology@ 42 modeling, Finite Element Analysis, #apid
5rototyping, and mold flow simulations (depicted "elow). And on a simpler leel,
sharing "ytes "etween designer, engineer, and manufacturer is argua"ly faster
and cheaper than sharing atoms.
Figure 2.8: Analysis &yto *hair
&old flow simulation simulates how molten material will flow in a mold
caity. This can tell a manufacturer how long it will taAe to mold a part, and if
there will "e any pro"lems associated with the material cooling too fast. Finite
element analysis proides insights into how an o"'ect will perform when arious
forces are applied. )ince this is all simulated in irtual space, it saes product
deelopers lots of time and money. The plastic supplier, (A)F, played a Aey
role in maAing sure the formula of plastic had the characteristics needed@
C"A#TER 3
*ET"O$OLOG< > STU$ENTS C"AIR 44T* 4E*A*AN
3.1 I%&r'(u)&i'%
The research methodology re!uires gathering releant data from the
pacified documents and compiling data"ases in order to analyse the material
and arrie at a more complete understanding and historical reconstruction of the
analysis of chair. 2ata collection will consist of sureys, from classroom
o"serations and interiews, as well as 'ournal logs from analysis of chair.
In order to achie the o"'ecties that hae "een stated in the pro'ect
"efore, efficient and effectie methodology must "e well carried out. (elow are
the methods and approaches that will "e applied during this research and it will
"e performed in a flow.
OPTIMIZATION
3.2 #r'6e)& F!': C3ar&
Figure 3.1: 5ro'ect Flow *hart
START
START
COLLECT
DATA
ANALYZ
E
ANALYZ
E
MODELLI
NG
MESHING
SUITABL
E
SUITABL
E
INVENTO
R
RESULL
T
RESULL
T
OPTIMIZATIO
N
CORRECTI
ON
CORRECTI
ON
NO
YES
NO
YES
YES
NO
NO
YES
In completing the pro'ect, two "asic process inoled that is confirmation
stage and optimization stage. This stages was created to ensure the
optimization done are "ased on actual pro"lem and the optimization is fully
capa"le to cater the arise issues.
In confirmation stage, the current design was created using *A2 software
together with the meshing "efore starting the analysis process using Finite
Element Analysis (FEA) A.T,2E)$ I1%E1T,#. This stage was to ensure that
the result o"tained were almost the same as the current pro"lem that in the
fracture point.
Figure 3.1: Autodest Inentor
7ith this result, improement can "e made to the critical areas and
resulting a "etter design and relia"ility. This process were included in
DESIGN ANALYSI
S
RESUL
T
RESUL
T
END
END
YES
optimization stage, where new design will "e proposed in order to oercome the
pro"lem arise in current design.
3.2.1 Li&era&ure Re2ie: > I%+'r-a&i'% a%( )'-.re,3e%,i'%
The information has "een carried out from many of sources such as
'ournals, "ooAs, internet and preious reports. The information needed are the
way of generating the model of chair "ase, the standarts that must "e followed
in designing the model, the fundamentals of the chair "ase, the types of
materials and ways of forming the chair "ase that are commonly used in
industry.
Figure 3.2: *hair 2etail
CHAIR BASE
WHELL
SEAT PLACE AND SCREW
LIFT
BACK REST
SEAT
STRUCTURE
Figure 3.3: 5arts of *hair
(esides that, we wide understanding of the new technologies of the chair
"ase is re!uired in order to gain more information needed. All the standards to
design the chair "ase must "e understood precisely as long as it the main focus
in the study
3.2.2 #ar& *'(e!i%g
After all the parameters are calculated and measured, the model of chair
"ase has "een performed "y using the *A2 software Autodest Inentor .
Autodest Inentor friendliy interface software and easy to draw the re!uired
model including solid modeling, surface modeling and other types of modeling
"ut anly solid modeling is used in generating the model of chair "ase.
Fr!" S#$% C&'#r B'(%
3.2.3 *'(e! A%ai/,i, a%( Si-u!a&i'%
In this study Autodest Inentor is used to analyze and simulated model.
The model will "e imported to the finite element application and can "e started
to analyze "y determinning the parameter re!uired such asa material uesd,
applied constraits, load and so on. ,nly the static analysis has "een carried out
in the study
Autodest Inentor offers much thah simply an FEA engine. Autodest Inentoris
really a design tool since it will allow parametric atudies as well as design
optimization to "e set up !uite easily. &oreoer, unliAe many other commercial
FE& progeram where determining accuracy can "e difficult or time consuming,
Autodest Inentor does not currently hae the a"ility to handle non:liner
pro"lem.
3.2.4 I%&er.re&a&i'% a%( ,/%&ge,i, Re,u!&
,nce the solution of the model according to applied "oundary conditions
and paremeters hae "een o"tained, the ariation of streese along the structure
can "e examined and inestigated. Then, further analysis will "e deeloped to
get the "est result "y modifying the parameters or factorsthat effect the stress
concentration and distri"ution. This will "e "ased on the experimental procedure
or the ro"ust design techni!ue. The main o"'ectie is to reduce the stress on the
chair "ase and the produces high !uality chair "ase
3.2.5 E2a!ua&i'% a%( C'%)!u,i'%
Ealuation for the optimum result must "e done to maAe a conclusion of
oerall studies, discussion of the study and whether the targets or o"'ecties
hae "een achied or not. After that, documetation must "e done in order to
record all the data and the results. 2ocumentation is ery important to show how
the study has "een carried out.
C"A#TER 4
*O$ELING OF STU$ENTS C"AIRS AT 44T* 4E*A*AN
4.1 *'(e!i%g '+ C3air,
In this research, a deeloped student chair using AutodesA Inentor The
students chair is modeled geometrically the same as the actual student chair at
$$T& $emaman. Figure 6./ shows the wire frame rendering model specifies
the appearance of the students chair and Figure 6.3 shows the shaded
rendering model specifies the appearance of the model as shaded com"ustion
cham"er.
Figure 6./@ 7ire frame rendering model of the student chair
Figure 6.3@ &odeling iew of the student chair
4.2 S.e)i+i)a&i'% *'(e!i%g
This type of configuration is generally used in modern chair. The chair
length is +B6;0mm, and the height is 2B 3<;8 mm in this modeling. Figure 6.4
shows the three iews of wire frame rendering and Figure 6.6 shows four iews
shaded rendering for students chair part using Autodest Inentor software.
Figure 6.4@ Three iews wire frame rendering models
4.3 *e,3e( *'(e!i%g '+ S&u(e%& C3air
The meshed model used element of tetChy"rid type T-rid in complex
region and also hexCwedge type cooper in the remaining region. Figure 6.8
shows the meshed model of the student chair.
Figure 4.5: &eshed model of the )tudent *hair
4.4 *a&eria!
&aterial type specification defines the physical operational characteristics
of the model. Figure 6.; shown the material data of the chair.
Figure 6.;@ Types of material
4.5 Crea&e '+ Si-u!a&i'%
After finishing the meshing process, the analysis simulation is carried
out to find the concentrated stress and safety factor of the student chair. Figure
6.G shown the analysis safety factor student chair,
Figure 6.G@ Analysis student chair
4.11 Si-u!a&i'% F!': C3ar&












































Figure 6./4@ Flow *hart of 5ro'ect
S")$* $'"' +'! ,%
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(")$%!" +&'#r '!'.*(#(
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A!'.*7% "&%
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S%'r+& #!1r2'"#!
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2'"%r#'. '!$ 1r+%9
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R%+r$ r%'$#!/ 1r2
'!'.*7%(.
C"A#TER 5
ANAL<SIS OF T"E STU$ENTS C"AIR
5.1 Re5uire-e%& ,a-.!e +'r)e, &' '&ai% re,u!& +r'- SIRI* S&a%(ar(
Ta"le 6 shown data will "e used for the analyze using the software
Autodest Inentor. The data is collect from the )I#I&.
Ta!e 4: 2ata analysis
BIL
SEAT FORCE
0 N 1
BAC4
FORCE 0 N 1
RE*AR4
/ /800 0
Frame used is mild steel,
"acA rest and seat is
polypropylene
3 /400 430
Frame used is mild steel,
"acA rest and seat is
polypropylene
4 //00 //00
Frame used is mild steel,
"acA rest and seat is
polypropylene

Figure 5.1: *omparing 2ata Analysis for &ild )teel
From the analysis we hae done, we found that the most critical path occur is
at the frame "etween seat and "acA rest. For an optimization, we tried to change
the material of the frame. =ere we tried for two types of different material which
is Psteel high strength low alloyQ and PA() 5lasticQ. The result o"tained for "oth
materials is shown in the next result.
5.2 S&ee! "ig3 S&re%g&3 L': A!!'/
Figure 5.1: *omparing 2ata Analysis for )teel =igh )trength +ow Alloy
Figure 5.1: *omparing 2ata Analysis for A() 5lastic
#esult for the lowest ,a+e&/ +a)&'r o"tained from the analysis "ased on
SIRI* re!uirement can "e summarise in the ta"le as follow
Ta!e 5: *omparing &aterial
)eat force B
/8001
(acA Force B 0
)eat force B /4001
(acA Force B 4301
)eat force B //001
(acA Force B
//001
&ild steel 0./H 0.33 0.0;
)teel high strength
low alloy
0./8 0.3H 0.08
A() 5lastic 0.// 0./ 0.04
From the result, there is no much different "etween "oth material mild steel
and steel high strength low alloy while for the A() plastic it shows that a little "it
difference which is a little "it lower than the preious two materials. There is one
similarity for three of them which is the critical point is at the same region. It
means that region has low safety factor and it might fail due to the usage.
5.3 C'-.ari%g $a&a
5.3.1 Sa-.!e re,u!& +r'- EN1728:2??? ,&a%(ar(
Bi! Sea& F'r)e Ba)7 F'r)e Re-ar7
/ /000 400 1, 2EFE*T)
3 /;00 8;0 1, 2EFE*T)
4 3000 <00 1, 2EFE*T)
#esult performed from stress analysis using inentor software "ased on
E1/<3G@3000 standard.
Forces
&aterial
5.3.2 Fra-e u,e( i, -i!( ,&ee!@ a)7 re,& a%( ,ea& i, .'!/.r'./!e%e
5.3.3 Fra-e u,e( i, "ig3 S&re%g&3 L': A!!'/
5.3.4 U,i%g :''( a, &3e ,ea& a%( a)7 re,&

Bi! Sea& F'r)e Ba)7 F'r)e
Re-ar7 A
L':e,& Sa+e&/ Fa)&'r
/ /000 400 0.38
3 /;00 8;0 0./4
4 3000 <00 0./
BIL SEAT FORCE
BAC4
FORCE
RE*AR4 A
LO9EST SAFET<
FACTOR
/ /000 400 0.46
3 /;00 8;0 0./G
4 3000 <00 0./6
BIL SEAT FORCE
BAC4
FORCE
RE*AR4 A
LO9EST SAFET<
FACTOR
/ /000 400 0.//
3 /;00 8;0 0.0;
4 3000 <00 0.08
Figure 5.1: *omparing 2ata Analysis for &ild )teel
Figure 5.1: *omparing 2ata Analysis for =igher )trength +ow Alloy
Figure 5.1: *omparing 2ata Analysis for 7ood
#esult for the lowest safety factor o"tained from the analysis "ased on
EN1728:2??? ,&a%(ar( can "e summarise as follow
)eat force B
/0001
(acA Force B 400
)eat force B /;001
(acA Force B 8;001
)eat force B 30001
(acA Force B <001
&ild steel 0.38 0./4 0./
)teel high
strength low
alloy
0.46 0./G 0./6
A() 5lastic 0.// 0.0; 0.08
From the result, there is a little "it different "etween these three materials
mild steel and steel high strength low alloy and the A() plastic. The highest
alue for safety factor o"tained "y the material Psteel high low alloyQ. There is
one similarity for three of them which is the critical point is at the same region.
From on the sample results from E1/<3G@3000 standard, there is no defect on
the test "ased on the forces "ut "y comparing the analysis that we hae done,
there might occur a failure at the lowest critical region.
Forces
&aterial
BAB 6
CONCLUSIONS AN$ RECO**EN$ATIONS
6.? I%&r'(u)&i'%

The Aey o"'ecties of design deelopment process were to reduce the
total olume of the chair structure, maintain the %on &ises )tress to accepta"le
alue, using the optimum alue of material strength, reduce the material
exposed to the increasing of the %on &ises stress as it is the factor that
contri"utes to the failure of chair and also to increase the alue of strength used,
thus offering greater a"ility to chair manufacturer to reduce the cost of material
used as it reduced the material used.
6.2 Su--ar/ a%( C'%)!u,i'%
The material characteristic of the chair used was inestigated. The
property of yield strength which contri"utes to the material failure was
understood, in the mean of inestigation the concentrated stress and
consideration of safety factor. The purposed of the study which to examine the
effects of arious geometry design and operational parameters which cause
failure of chair and performance instead of optimize the material strength used is
completed. .sing Finite Element Analysis (FEA), the performance of irtual
prototypes was examined to ealuate the effectieness and efficiency of chair in
the application ro"ust design techni!ue.
*onclusions from the study are@
a) As anticipated, the main factor contri"ute the cahir failure is the high
concentration alue of %on &ises )tress. ,ther factor is the extreme
ha"it of sitting occurs in the sitting application.
") The results show that the new optimize design of chair can reduce the
weight of material used and increase the alue of %on &ises )tress to
the accepta"le upper limit alue (yield strength)
c) =igh performance and lower production cost of the chair successfully
deeloped as the main failure of stress concentration is reduced and
the optimum strength of the material is optimally used.
The findings reealed "y this study hae helped guide the design of lower
cost production chair using the new application of FEA techni!ue. &uch of the
credit for the success of the pro'ect is contri"uted to the ersatile and noel
ways in which the computed FEA data could "e isualized and more clearly
understood.
6.3 Re)'--e%(a&i'%
6.3.1 Re,ear)3 I-.r'2e-e%&
As for suggestion to improe present system, some of the way to handle
the pro"lem is lined up "elow@
a) #edesign of the model must taAe on consideration of fatigue strength
of the material instead of considering taAing the maximum safety
factor of repeated loading (cyclic load).
") The dimension of actual part must "e collected from the original
manufacturer instead of manually measure the sample of the chair.
c) All the data re!uired for the FEA must "e collected properly and
completely.
REFERENCE
/. $enneth-. (udinsAi, &ichadl$. (udinsA, E%gi%eeri%g *a&eria!,, 5rentice
=all300/, )addle #ier, 1ew Nersey, *olum"us, ,hio
3. A1)9) S&ru)&ura!A%a!/,i,Gui(e, #elease 8.<, 300/, A1)9), Inc.
*anons"urg, 5A
4. (odig, N.? Nayne, (. A. /HH4@ *e)3a%i), '+ 9''( a%( 9''( C'-.',i&e,@
$rieger 5u"l. *omp. &ala"ar, Florida.
6. =.7.&orrow, #o"ert 5. $oAernaA, 300/ )tatics and )trength of &aterials
8. &A+A9)IA1 )TA12A#2, &) /<//@ 5A#T /@3004, Fur%i&ure >'++i)e )3air
0a(6u,&a!e1, 5A#T 3@ $i-e%,i'%= (e&er-i%a&i'% '+ (i-e%,i'%
2epartment ,f )tandards &alaysia
;. &A+A9)IA1 )TA12A#2, &) /<//@ 5A#T /@3004, Fur%i&ure >'++i)e )3air
0a(6u,&a!e1, 5A#T 3@ Sa+e&/ Re5uire-e%&, 2epartment ,f )tandards
&alaysia
<. &A+A9)IA1 )TA12A#2, &) /<//@ 5A#T /@3004, Fur%i&ure >'++i)e )3air
0a(6u,&a!e1, 5A#T 3@ Sa+e&/ Te,& *e&3'( 2epartment ,f )tandards
&alaysia