Design analysis

One of the important key to ensure the survival of a product is design analysis of the product.
This process should be done before fabricated the product to avoid product failure and repetitive work.
It also to prevent excessive cost for the project. The vital part on the product is selected to run analysis
to test how much the part can withstand force before it cracked or end up as a failure. In this project, the
top part plays important role where it receives tension force from the hydraulic jack and static analysis
being run in order to determine maximum of force can be applied. The analysis also can show how
much displacement occur when receive force. The material used is steel because this material has high
resistance properties compare to other material. By using catia V5 analysis and simulation, two
visualization can be shows which are displacement analysis and Von Misses Stress analysis. Finite
Element Analysis (FEA) is physical simulation concept using Finite Element Method (FEM) that help
to reduce minimize number of real prototype and provide early information about the product.

Figure 10: Stress-Strain diagram

Analysis of van misses stress to predict if the used material will yield or fracture. This concept
is similar with a graph of stress-strain diagram. To determine the result, it all shows and refer from
stress-strain diagram. According to the theory, von misses stress of material below load is same level or
higher than the yield limit of same material then material will yield. For this case, position of yield
strength is located between elastic and plastic region where maximum yield strength occurs.
 Figure 12: Von Mises stress analysis.

Figure above shows finite element analysis on top part where tension of force applied to push
the cutter blade. The part used mild steel low medium carbon as it’s material. For the case, maximum
yield strength is placed between elastic and plastic region and the value of maximum yield strength for
mild steel commonly used is 370 Mpa. Hydraulic jack provide total amount of force 39240 N and one
end of the part is clamped to avoid part moving during analysis. From the above value, the highest von
misses stress is 352 Mpa and lowest value is 2.85 Mpa. Blue colour indicated safe zone and red colour
indicate dangerous point and for the analysis red zone located at the end of the part. This is because the
location near to source of force. The highest value von misses stress not exceed yield strength of mild
steel show the part till safe.
 Figure 13: Displacement magnitude

Next, visualization of displacement magnitude also being shown to improve theoretical safety of
the part. This displacement is to ensure the top part can avoid a high displacement because if it
happened, product life span will be less. The translational displacement highest value is 2.09 mm at the
end of the part. All those value more than 1 mm and can be consider top part having medium
displacement and cannot be neglected. Refer to stress-strain diagram, part can return to original set in
elastic region. In this matter, only displacement ta blue colour had probability to return in original
shape. As for the red zone, it is dangerous and can lead to permanent deformation and the cracked if
passes the limit.
Sample Calculation

3500 N/m

R1
0.3 m
Assump
tion

1. Tension force given by hydraulic jack 3500 N

2. Force distributed all over the part.
3. One fixed support

Find reaction force R1 and reaction moment,

Σ forces = 0 (upward forces +ve)
3500N – R1 = 0
RI = 3.5kN

Σ moments = 0 (take moments about the fixed support at the left hand end - clockwise moments +ve)
(3500 x 0.3) - Mre = 0
M = 1.05 kNm (clockwise moment)

Find shear force and bending moment, assume V and M are unknown.
At x = 0.15 m, V1 =?

Σ forces = 0
3.5kN – (3.5kN/0.15) + V1 = 0
V1 = 19.83kN
Σ moments = 0
(3.5kN x 0.15) – (23.33kN x 0.075)- 1.05kNm + M1 = 0
M1 = 2.28kNm
At x = 0.3 m, V2 =?

Σ forces = 0
-3.5kN + 3.5Kn + V2 = 0
V2 = 0
Σ moments = 0
(3.5kN x 0.3) –1.05kNm + M2 = 0
M2 = 0

Shear force and bending moment diagram

V (m)

1.05kNm
19.93kN

M (N/m)

47.04
 Mc bh 3
σ= ,I=
I 12

0.01 x (0.033 )
I= = 2.25 x 10^-8 m4
12

1.05 k x 0.015
σ= = 700 Mpa
( 2.25 x 10−8 )

Calculate factor of safety, FS.

allowable shear stress

FS =
maximum shear stress

700
= = 2.8
250

Allowable shear stress for mild steel commonly used 250 Mpa. The good value for factor of
safety range from 1-5. This project had good factor of safety.