STATIC AND DYNAMIC ANALYSIS OF A STEPPED SHAFT

A report submitted to Visvesvaraiah Technological University,Belgaum for in partial fulfilment for the award of degree

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING Report Submitted by

Mr. Abhinav Anil Tendulkar (1RV04ME002) Mr. Arun Narayanan (1RV04ME013) Mr. Akhil Rajagopal k (1RV04ME005) Mr.Ashley Jose Murickan (1RV04ME121)

Fourth Year B.E in Mechanical Engineering

UNDER THE GUIDANCE OF Mr.T.G.Gangadhar

Lecturer Department of Mechanical Engineering R.V.College of Engineering Bangalore

Mr.S.Lokesh
Assistant Manager Kirloskar Electric Company Ltd Bangalore

DEPARTMENT OF MECHANICAL ENGINEERING R.V.COLLEGE OF ENGINEERING JUNE 2008

R.V.COLLEGE OF ENGINEERING

CERTIFICATE
This is to certify Mr.Abhinav Anil Tendulkar, USN 1RV04ME002, Mr. Akhil Rajagopal, USN 1RV04ME005, Mr. Arun Narayanan, USN 1RV04ME013, Ashley Jose Murickan, USN 1RV04ME0121, have successfully completed the project entitled STRUCTURAL ANALYSIS OF A STEPPED SHAFT undertaken at Kirloskar Electric company Ltd as prescribed by the Visvesvaraya Technological University for the award of the degree Bachelor of Engineering( B.E) in the year 2007-08.It is certified that all

corrections/suggestions indicated for internal assessment has been incorporated in the report deposited in the department library. The project report has been approved as it satisfies the academic requirements in respect of project work prescribed for the above said degree.

Name and signature of Guide

Name and Signature of the HOD

Mr T. G. Gangadhar
Lecturer Engineering Department Department of Mechanical Engineering R. V. College of Engineering Banagalore

Dr. B. Anand
Head of the Mechanical R. V. College of Engineering Bangalore

DECLARATION
We hereby declare that the dissertation entitled STRUCTURAL ANALYSIS OF A STEPPED SHAFT embodies the report of our project work carried during the VIIIth semester of our B.E. course. The project, undertaken at Kirloskar Electric Ltd, was carried out independently by us under the guidance of Mr.Lokesh, Design Engineer at Kirloskar Electric, and Mr. T. G. Gangadhar, Department of Mechanical Engineering, R.V.College of Engineering, Bangalore.

Place: Bangalore

Abhinav Anil Tendulkar

Akhil Rajagopal K

Arun Narayanan

Ashley Jose Murickan

ACKNOWLEDGEMENT
This project has been possible mainly due to the help and support received from various people whom we would like to express our gratitude. Firstly, we would like to express our sincere thanks to Kirloskar Electric Company for giving us an opportunity to work on an interesting project. Mr Lokesh S, our guide in the company, has been extremely co-operative and helpful. We would like to express our gratitude towards Mr. Lokesh for the constant guidance and support provided through the course of the project.

We would like to thank Mr. T. G. Gangadhar, department of Mechanical Engineering, R. V. College of Engineering, whose expertise in Ansys has been extremely helpful in the timely completion of the project.

The department of Mechanical Engineering, headed by Dr. B. Anand, has been encouraging and co-operative in our endeavour. Hence, we would like to thank Dr. B. Anand, Head of Mechanical Engineering Department, and all other teaching and non-teaching staff who have helped us in the project.

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SYNOPSIS

Motors are devices which convert electrical energy into mechanical energy. The mechanical energy produced is transmitted using a shaft. The aim of our project is to perform static and modal analysis on the shaft to determine the deflection, stresses and factor of safety; the other objective of the present work is to determine the natural frequencies and modal shapes to understand the vibration characteristics. The project is undertaken at Kirloskar Electric Ltd. The shaft used to transmit power is a stepped shaft comprising of 25 cross-sections of varying diameter. The transverse loads acting on it are due to the weights of devices mounted on the shaft and the unbalanced magnetic pull; torque is also applied on the shaft. Ansys, an FEA package (Finite Element Analysis), is used to perform the analysis. If the value of stresses, deflection or factor of safety is found to be outside permissible limits, then the shaft has to be re-designed. If the factor of safety is found to be well above 4, then the maximum power that the shaft can transmit is also found out.

The geometric modelling of the stepped shaft is carried using Ansys 10.0. The finite element modelling of the shaft is done using Ansys 10.0 The static and modal analysis is also done using Ansys 10.0

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CONTENTS
CERTIFICATE DECLARATION ACKNOWLEDGEMENT SYNOPSIS CONTENTS LIST OF FIGURES LIST OF TABLES COMPANY PROFILE

CHAPTER 1 1 Introduction 1 2 2 2 3

1.1 Components 1.2 Characteristics and System Requirements 1.3 Objective of the Problem 1.4 Scope of the Project CHAPTER 2 2 Fundamentals of Finite Element Method

4 4 4 4 5

2.1 Introduction 2.2 History 2.3 Governing Differential Equation Formulation 2.4 Displacement Method

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2.5 Principal of Potential Energy Method 2.6 Mathematical Model 2.7 Discretization 2.8 Elements 2.9 Nodes 2.10 FEA as applied to three member truss 2.11Applications 2.12 CAD and FEA in industry

5 6 8 9 10 11 16 17

CHAPTER 3 3 Introduction to Ansys 20 20 20 21 21 22 22 22

3.1 General Description 3.2 Pre-Processing 3.3 Input Data Structure 3.4 Element Library 3.5 Material Models 3.6 Kinematics Constraints 3.7 Types of Loading

CHAPTER 4 4.1 Unbalanced Magnetic Pull 4.2 Von-Mises Stress 25 25

CHAPTER 5 5 Introduction to Modal Analysis 27 27 27 28 28

5.1 Modal Analysis using FEM 5.2 FEA Eigen Systems 5.3 Comparison to Linear Algebra 5.4 Methods of Solution

CHAPTER 6 6 Modelling of the Shaft in Ansys 30 30 30 35

6.1 Changing the orientation of workplane 6.2 Creating the solid model of shaft 6.3 Finite Element Modelling

CHAPTER 7 7 Static Analysis 37 37 38 42 43 43 44 45

7.1 Application of Boundary Conditions 7.2 Application of Forces 7.3 Application of Constraints 7.4 Solution 7.4.1 Deformation 7.4.2 Stresses 7.5 Critical Speed

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CHAPTER 8 8 Analysis while Torque 47 48 49 50 51 52 53 54 55 56 57

8.1 Applying Loads and Boundary Conditions 8.2 Application of Forces 8.3 Application of Torque 8.4 Application of Constraints 8.5 Solution 8.5.1 Deformation 8.5.2 Bearing Reactions 8.5.2 Stresses 8.6 Factor of Safety 8.7 Conclusion

CHAPTER 9 9 Modal Analysis 58 59 60

9.1 Material properties 9.2 Results and Discussion

CONCLUSION SCOPE FOR FUTURE WORK BIBLIOGRAPHY REFERENCES

62 63 64 65

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COMPANY PROFILE
Kirloskar Electric Company Limited (KEC) is one of India's leading manufacturers of electrical and power equipment. Established in 1946 by Mr. Ravi L Kirloskar, Kirloskar Electric manufactures AC Motors, AC Generators, DC Machines, Traction Equipment, Electronics, Switchgear, Transformers and undertakes turnkey Electrical Projects.

In 60 years, the company has built on its core capabilities of prime technological and engineering skills complemented by world class manufacturing facilities. Kirloskar Electric products have made more than a significant contribution to India's rapidly growing economy. Today, Kirloskar Electric is capable of delivering a wide range of custom engineered products that meet and exceed global standards at very competitive prices.

Kirloskar Electric was the first company in India to manufacture AC Motors way back in 1948. Since then it has manufactured millions of motors for domestic and International Market. Its initial technology support from BRUSH Electric UK & technical collaborations with NEI Peebles Electrical Machines, Scotland and AEG of Germany enables KEC to develop high capacity motors for various applications. A strategic alliance with FUJI Electric of Japan enabled the company to absorb and implement state of art technology for motors which has been proved to be on par with global competition.

The product range in capacity and variety caters to multitude applications. KEC has electric motors for every conceivable application and industry. The wide industrial range is from 0.12 to 20000 kW in frames 63 to 1250. Motors are offered in open type, closed type and heat exchanger type enclosures. Voltages range from 340 to 13800 V. Class F insulation being standard for all motors, class H insulation is also offered for low voltage motors.

The rugged and highly reliable higher range motors are specifically designed for exacting duties. The modular design totally enclosed air to air heat exchanger is the first choice of industry for the more arduous applications. Compact rib cooled motors with unique internal cooling are used for duty atmospheres and other harsh conditions.

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Kirloskar electric offers AC Generators from 1kVA to 20MVA, voltage from 220 to 11000 V, and speed from 3000 rpm down to 375rpm, frequencies 50 or 60Hz., or even special frequencies like 200 or 400Hz. These machines can have enclosures of open and closed type with air or water cool arrangements. Mechanical construction can have single or double bearing arrangements and variety of excitation system both brushless and brush type, with class F or class H insulation, meeting the performance they requirements of national and international standards. In the aspect of dimension, size, weight, aesthetics and performance they are comparable to the best of the world.

The Special motors list includes Roller Table motor, Mud Gun motor, Bell Annealing Furnace motor for steel mill applications. When India faced sanctions on supply for equipment for Nuclear Power Plants, KEC developed special Canned Pump Motors. Motors like explosion proof, increase safety and non-sparking ones used extensively in hazardous areas like coal mines, oil mines and petrochemical industries are available in a wide range. Specially designed adjustable speed drive motors in large numbers are working in various steel plants and other industries.

KEC is the only company in India and one among the 18 in the whole world to have the unique certified facility for efficiency testing of induction motors up to 50hp. The laboratory has been certified by NVLAP (National Voluntary Lab Accreditation Program), USA.

Applications
Industries
: Agriculture, Construction, Cement, Paper, Petrochemicals, Steel, Sugar, Textile. Nuclear, Thermal. Cinema, Gas Station, Hospitals, Hotels, Mill, Telecom. Auxiliary power to fire armaments from land & Sea.

Power Plants : Utilities Military

: :

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LIST OF FIGURES
Fig 1.1 Front view of the stepped shaft Fig 6.1 Keypoints created for solid modelling Fig 6.2 Solid model (Isometric view) Fig 6.3 Finite element model Fig 6.4 Finite element model (front view) Fig 7.1 Various components mounted on shaft Fig 7.2 External fan mounted on shaft Fig 7.3 Model with the loads Fig.7.4 The uniformly distributed load Fig 7.5 Constraints as applied on the left bearing Fig 7.6 Deflection (front view) Fig 7.7 Von-mises stress plot Fig 7.8 Von mises stress(Isometric View) Fig 8.1 Torque applied on the nodes Fig 8.2 The model after application of boundary conditions Fig 8.3 Isomeric view of loads Fig 8.4 Deflection (Front View) Fig 8.5 Deflection (isometric view) Fig 8.6 Shear stress distribution (isometric view) Fig 8.7 Von-mises stress distribution (isometric view) Fig 9.1 Constrained Model for Modal analysis Fig 9.2 1st Mode Fig 9.3 2nd Mode Fig 9.4 3rd Mode

LIST OF TABLES
Table-6.1 Keypoints and their location Table-6.2 Keypoints and their location for constraints Table-6.3 Keypoints and their location for forces Table-6.4 Keypoints and their location for torque Table-6.5 Dimensions of cylinders Table-7.1 Forces and their source Table-7.2 Node numbers for application of forces Table-7.3 Nodes for application of UDL Table-8.1 Forces and their source Table-8.2 Node numbers for application of forces Table-8.3 Node numbers for application of UDL Table-8.4 Bearing Reactions Table 9.1 Modal Frequencies

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