Project Rampway

ME 450Finite Element Analysis Spring 07 Aaron Emmons, Bryce Young and Eric Bush Professor Dr. K. Nema Monday April 30th, 2007

Presentation Summary
Eric
Objective Introduction Theoretical Concepts Model Details / Material Properties / Cost

Aaron
Loading Cases Results and Discussion

Bryce
Finish Results and Discussion Impact Statement Present Conclusions

Objectives
Utilize knowledge learned through Mechanical Engineering to obtain experimental results on a realworld example Examine two different materials to optimize a motorcycle ramp for structural integrity and usability Accomplished by structural Finite Element Analysis of both aluminum and steel ramps through Pro/E and Pro/E Mechanica

Introduction
Project Background / Goal
1. To produce the groundwork for material selection and load limits for a motorcycle loading ramp. (pickup truck)
Use Finite Element Analysis to understand performance of aluminum and steel Compare Weight and Cost

Previous Work
1. Finite Element Analysis of experimental objects in ME 450

Theoretical Background
Displacement in terms of Cartesian components:

Von Mises Stress in 3 dimensions:

Theoretical Background Cont.

Factor of Safety:
Yield _ Stress _ of _ Material factor _ of _ safety Maximum _ Stress
Relation between Von Mises, Yield Strength, and factor of safety:

Model Details
Table 1: Ramp Dimensions
Ramp Dimensions Dimension Length Width Top Surface Area metric 2.2350m 0.3048m 0.3786m^2 SI 7.33ft 1.00ft 4.075ft^2

Volume

0.009m^3

0.318ft^3

Model Details II
Table 2: Material Properties
Material Properties (3) property E p poison ratio yield strength Steel 200 7861.1 0.29 434 703 Aluminum 72.4 2795 0.33 414 469 Mpa Mpa unit Gpa kg/m^3

ultimate yield strength

Model Details III

Table 3: Steel vs. Aluminum Properties

Material Aluminum Steel

Weight Weight Cost (kg) (lb) ($/lb) 25.06 70.48 55.21 155.28 17.50 7.77

Raw Material Cost ($) 966.15 1206.51

Model Details IV
Mesh
Automatically generated by Pro-Mechanica at 1300 elements Multi-pass adaptive solution

Model Loading
Uniform Pressure Load, Central Localized Load and Offcentered Localized Load Ramp is fixed for zero displacement at the base as well as the top angled flange to simulate ground and truck bed loading conditions

Loading Conditions
Uniform Pressure Load used to establish initial maximum load and force per unit area Central Localized Load set at approximately 60 inches (average wheel base of motorcycle) to simulate motorcycle tires Off-Center Localized Load real world condition of loading motorcycle up ramp under the assumption tires will not follow center of ramp

Results and Discussion

Von Mises Stress and Displacement Analysis for Aluminum vs. Steel Uniform Pressure Load Central Localized Load Off-center Localized Load

1. 2. 3.

Uniform Pressure Load

Aluminum
Von Mises Stress Analysis (Load = 16000 N/m^2)

Uniform Pressure Load

Steel
Von Mises Stress Analysis (Load = 17500 N/m^2)

Uniform Pressure Load

Aluminum
Displacement (Load = 16000 N/m^2)

Uniform Pressure Load

Steel
Displacement (Load = 17500 N/m^2)

Results of Uniform Pressure Load

Aluminum
Max N Load (N/m^2) Displacement (m) Max Stress (MPa) 5512 16000 0.03703 413 414 1 Yield Stress (MPa) Factor of Safety

Steel
Max N Load (N/m^2) Displacement (m) Max Stress Yield Stress (MPa) Factor of Safety

(MPa)
6029 17500 0.0148 433.5 434 1

Central Localized Load

Von Mises Stress Analysis (Load = 4479 N) Aluminum Steel

Central Localized Load

Displacement (Load = 4479 N)

Aluminum

Steel

Results of Central Localized Load

Aluminum
Max N Load (N/m^2) Displacement (m) Max Stress (MPa) Yield Stress (MPa) Factor of Safety

4479

13000

0.00966

129.3

414

3.2

Steel
Max Max Yield Factor

Load (N/m^2)

Displacement (m)

Stress
(MPa)

Stress (MPa)

of Safety

4479

13000

0.003515

130.4

434

3.33

Off-Center Localized Load

Von Mises Stress Analysis (Load = 4479 N) Aluminum Steel

Off-Center Localized Load

Displacement (Load = 4479 N)

Aluminum

Steel

Off-Center Localized Load

Bending due to off-center loading

Results of Off-Center Localized Load

Aluminum
Max N Load (N/m^2) Displacement (m) Max Stress (MPa) Yield Stress (MPa) Factor of Safety

4479

13000

0.00995

141.3

414

2.93

Steel
Max N Load (N/m^2) Displacement (m) Max Stress (MPa) Yield Stress (MPa) Factor of Safety

4479

13000

0.00362

142.2

434

3.05

Impact Statement
This project is simulates a material selection and design validation process that a manufacturer would use in choosing a material and verifying the functional limits of a design prior to production.

An FEA analysis aids in producing a product that performs as advertised, which allows the production a safe and cost effective design that fulfills the needs of consumers.
Due to familiarity, Pro/E Mechanica was used to as the FEA software to perform the described analysis.

Conclusions
The highest magnitude of stress occurred at the intersection of the angled flange The largest displacements occurred at the center of the ramp. Cost - Aluminum cost less than steel by more than $240

Weight Steel out weighs aluminum by more than 100 lbs increasing the difficulties associated with normal use and transportation

Conclusions Cont.
Strength For the same design, steels structural properties are superior to aluminums allowing for higher load limits and smaller displacements under the load conditions produce by a 1000lb motorcycle.

Consider weight, cost, and loaded performance, aluminum proved to be the superior material for the motorcycle ramp. Aluminum motorcycle ramps are widely produced, indicating that manufacturers arrived at similar conclusions.

References
1. http://www.realclassic.co.uk/ridesfiles/rid es05011401.jpg 2. http://www.horizonsunlimited.com/newsle tter/images2003/2003-04-01_MaartenTwoWheeler.jpg 3. ME450 Lecture Notes via Oncourse

Questions???